Disassembly and Assembly Procedures for Sound Suppressed Idlers {0729, 4159} Caterpillar

Track-Type Tractor

D10T (S/N: RJG1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; MDG1-UP; JEL1-UP; JNS1-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

This guideline provides the Disassembly and Assembly procedures for the sound suppressed idlers. These idlers contain segments in order to reduce the noise level during operation. During the rebuild, always correct any conditions which may have caused the original failure or wear.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599, "Undercarriage Reconditioning Guide Binder (Prescription Only)"

Reference: Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers"

Reference: Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8586, "Removal, Installation, and Conditioning of Idler Bearings and Track Roller Bearings"

Reference: Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume"

Reference: Undercarriage Reconditioning Bulletin, SEBF8585, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals"

Reference: Information Release Memo, PELJ0902, "D11T/R/N Undercarriage Sound Reduced Idler and Sprocket"

Reference: Information Release Memo, PELJ0836, "D10T/R/N Undercarriage Sound Reduced Idler and Sprocket"

Reference: Technical Information Bulletin, TIBU6688, "Recommended Usage Of Cat Final Drive and Axle Oil Synthetic (FDAO Syn) For the Idlers On Certain D10R, D10T, D11R, and D11T Track-Type Tractors"

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 ones below is used to identify 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 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

Disassembly

Note: The true center line must be kept on all idler rebuilds for proper rebuild procedures. Measure from machined retainer surface on hub to establish the true center line of hub.

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Illustration 2	g01572076

1. Remove the plastic plug and the rubber stopper from the end of the shaft in order to drain the oil.
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   Illustration 3	g01577235

2. Remove the retainer bolts from the retainer on both sides of the idler.
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   Illustration 4	g01578333

3. Use a hydraulic press in order to remove the collars from both sides of the idler.

   Note: Use approximately 22240 N to 66720 N (5000.0 lb to 15000.0 lb) of force in order to remove the collars.

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   Illustration 5	g01578334

4. Remove the retainer from both sides of the idler.

   Note: The thrust washers are pinned to the retainer. Refer to Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers" in order to remove the thrust washer from the retainer.

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   Illustration 6	g01531253

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   Illustration 7	g02183514

5. Use 8T-0447 Dial Caliper As in order to measure inside diameter (AA) of the end collar and shaft diameter (BB). Refer to Table 4 and Table 5 for the correct dimensions. Replace the components if the components are not within specifications.
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   Table 4

   Specifications for the End Collar
   Sales Model	Part Number of the End Collar	Inner Diameter (AA)
   D11T	156-4653	100.40 ± 0.02 mm (3.953 ± 0.001 inch)
   D10T	107-9620	74.40 ± 0.02 mm (2.929 ± 0.001 inch)

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   Table 5

   Specifications for the Shaft
   Sales Model	Part Number of the Shaft	Diameter (BB)
   D11T	156-5351	100.5 ± 0.02 mm (3.96 ± 0.001 inch)
   D10T	154-3308	74.5 ± 0.02 mm (2.913 ± 0.001 inch)

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   Illustration 8	g01578377

6. Remove the large O-ring seals from each retainer assembly.
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   Illustration 9	g01578378

7. Remove the O-rings from each collar assembly.
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   Illustration 10	g01579126

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   Illustration 11	g01579128

8. Remove the Duo-cone seals from the retainer and collar assemblies.

9. Inspect each set of Duo-cone seals for reusability. Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals".

   Note: If the seals are reusable, the seals must be kept in matching pairs.

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   Illustration 12	g01579134

   Note: Measuring the clearance between the shaft and bearing with a 8H-8581 Feeler Gage.

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   Illustration 13	g03728241
   (L) Inside diameter of the bore of the idler (M) Width of idler hub (N) Bearing assembly inside diameter (P) Width of idler true center line from machined retainer face

   Note: The true center line must be kept on all idler rebuilds for proper rebuild procedures. Measure from machined retainer surface on hub to establish the true center line of hub.

   Note: Measuring the clearance between the shaft and the bearing using the dimensions in Table 7 and Table 8.

10. Measure the clearance between the shaft and the bearing. Refer to Table 6 for the correct dimensions.
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    Table 6

    Clearance Between the Shaft and the Bearing
    Sales Model	Clearance Minimum/Maximum
    D11T	0.49 mm to 0.61 mm (0.019 inch to 0.024 inch)
    D10T	0.44 mm to 0.56 mm (0.017 inch to 0.022 inch)

    Note: Table 7 and Table 8 include the dimensions in order to determine the clearance between the shaft and the bearing dimensionally. A feeler gauge may be used as a quick check for the clearance.

    If the clearance measurements are not acceptable, an evaluation will be necessary to determine the problem. The following procedures can be taken in order to correct the problem:

    • Recondition the existing bearing bore.

    • Recondition the bore of the idler and install new bearings.

    • Replace the idler shaft.

    Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8586, "Removal, Installation, and Conditioning of Idler Bearings and Track Roller Bearings".

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    Table 7

    Dimensions for Rebuilding the Idler
    Sales Model	Idler Assembly	Idler	Inside Diameter of the Bore (L)	Width of the Hub (M)	Part Number for the Bearing	Inside Diameter of the Bearing Assembly (N)	Width of Hub True Center Line (P)
    D11T	292-8088	292-8087	168.89 ± 0.04 mm (6.649 ± 0.002 inch)	402.00 ± 0.13 mm (15.827 ± 0.005 inch)	258-4614	162.82 ± 0.03 mm (6.410 ± 0.001 inch)	201.00 ± 0.065 mm (7.913 ± 0.003 inch)
    D10T	257-9829	257-9828	142.85 ± 0.04 mm (5.624 ± 0.002 inch)	326.00 ± 0.13 mm (12.835 ± 0.005 inch)	9W-4194	136.78 ± 0.03 mm (5.385 ± 0.001 inch)	163.00 ± 0.065 mm (6.417 ± 0.003 inch)

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    Table 8

    Specifications for the Shaft
    Sales Model	Idler Assembly	Shaft	Outside Diameter of the Shaft	Length of the Bearing Surface
    D11T	292-8088	156-5351	162.27 ± 0.03 mm (6.389 ± 0.001 inch)	377.00 ± 0.10 mm (14.843 ± 0.004 inch)
    D10T	257-9829	154-3308	136.28 ± 0.03 mm (5.365 ± 0.001 inch)	301.00 ± 0.10 mm (11.850 ± 0.004 inch)

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    Illustration 14	g01579193

11. Remove the shaft from the idler. If necessary, attach a hoist in order to help remove the shaft.

12. Wash all components in order to remove debris from the components.
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    Illustration 15	g01579194

13. Use isopropyl alcohol to clean the components. Dry with 162-5791 Shop Towel or use 265-2256 Wipers.

Removal of the Segments

Measure the wear of the idler. Record the wear of the idler. Use a large caliper in order to measure the diameter of the idler. Determine the wear rate of the idler from the usage and application of the idler. Verify that there is enough wear material on the segments until the next rebuild of the undercarriage. Refer to Table 9 for the measurements of wear of the segments. Refer to Information Release Memo, PELJ0902, "D11T/R/N Undercarriage Sound Reduced Idler and Sprocket" or Information Release Memo, PELJ0836, "D10T/R/N Undercarriage Sound Reduced Idler and Sprocket" for complete measurements of wear.

Illustration 16	g01573453
D11 bolt pattern

Illustration 17	g01573454
D10 bolt pattern

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Illustration 18	g01531776

1. Position the idler on a suitable work surface. Remove the outer bolts from the idler.

   For the D11, remove bolts (1), (4), and (5).

   For the D10, remove bolts (2).

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   Illustration 19	g01531798

2. Remove the inner bolts from the idler.

   For the D11, remove bolts (2) and (3).

   For the D10, remove bolts (1).

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   Illustration 20	g01531833

3. Remove the center guides from the idler.
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   Illustration 21	g01531835

4. Use 156-7100 Slide Hammer Puller Gp in order to remove the bars.
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   Illustration 22	g01531921

5. Remove the segments from the idler.

Assembly

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Illustration 23	g01582733

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Illustration 24	g01582734

1. Apply 369-9450 O-Ring Assembly Compound to the new O-rings in order to install the new O-rings into the retainer and the collars.

   Note: Always use new O-rings in the retainers and collars.

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   Illustration 25	g01583933

2. Inspect each set of Duo-Cone seals for reusability. Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals".

   Note: If the seals are reusable, the seals must be kept in matching pairs.

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

   Note: Make sure that the toric ring is not twisted on the seal ring.

4. Install the Duo-Cone seal in the proper seal installer. Refer to Table 10 for the correct installation tool.
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   Table 10

   Duo-Cone Seal Installation Tool
   Sales Model	Part Number
   D11T	159-9843
   D10T	129-1340

5. Lightly dampen the lower half of the toric ring with isopropyl alcohol.
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   Illustration 26	g01584679

6. Use a firm, even pressure on the installation tool in order to install the Duo-Cone seal in the end collar.
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   Illustration 27	g01584680

7. Use a firm, even pressure on the installation tool in order to install the Duo-Cone seal in the retainer.
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   Illustration 28	g01584856

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   Illustration 29	g01584858

8. Use 8T-0447 Dial Caliper As in order to check the height of the assembled Duo-Cone seals in the retainers and the end collars. Take measurements at four 90 degree locations. The assembled height should be 11.50 mm ± 0.60 mm (0.453 inch ± 0.024 inch.)

   Note: The difference in height must not exceed 1.0 mm (0.04 inch). If the assembled height does not meet specifications, the Duo-Cone seals will need to be reinstalled.

9. Lightly lubricate the idler bearings with 8C-3698 Oil.
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   Illustration 30	g01584895

10. Carefully install the shaft into the idler.

    Note: The shaft may scrape bronze particles from the bearing. The bronze particles will cause failure in the idler.

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    Illustration 31	g01584954

11. Install the thrust washer onto the retainer assembly. Refer to Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers".
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    Illustration 32	g01584957

12. Slide the retainer assembly over the shaft and carefully move the retainer to the final position.
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    Illustration 33	g01584958

13. Use 5P-3931 Anti-Seize Compound on Bolt Threads.Tighten the retainer bolts.
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    Illustration 34	g01584975

14. Torque the retainer bolts to the specifications in Table 11.
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    Table 11

    Sales Model	Bolt Torque
    D11T	270 ± 40 N·m (200.0 ± 30.0 lb ft)
    D10T	135 ± 20 N·m (100.0 ± 15.0 lb ft)

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    Illustration 35	g02182654

15. Check for end play prior to the end collar installation. Refer to Table 12 for the correct end play specifications.
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    Illustration 36	g02182715

16. Use the 8T-5096 Dial Indicator Test Group or equivalent tool. Install the magnetic base onto the face of the retainer assembly. Adjust the arms and the indicator as shown.
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    Illustration 37	g02182777

17. The contact point of the dial indicator needs to engage the idler shaft.
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    Illustration 38	g02182855

18. Gently push the shaft away from the dial indicator. The shaft will stop when contact is made with the internal thrust washer on the opposing retainer assembly. When the shaft makes contact, apply preload to the dial indicator and adjust the dial to zero as shown.
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    Illustration 39	g02182845

19. Gently pull the shaft towards the dial indicator. The shaft will stop when contact is made with the internal thrust washer on the retainer assembly that the magnetic base is attached to. The dial indicator will show the amount of end play between the shaft thrust faces and the internal thrust washers.
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    Table 12

    Sales Model	End play
    D11T	0.23 mm to 1.29 mm (0.009 inch to 0.051 inch)
    D10T	0.31 mm to 1.21 mm (0.012 inch to 0.048 inch)

20. If the end play does not meet the specifications, the idler must be disassembled.
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    Illustration 40	g01585593

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    Illustration 41	g01585594

21. Wipe the entire seal face of the Duo-Cone seals in the retainers and the end collars with a clean towel. Use 162-5791 Shop Towel or 265-2256 Wipers .
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    NOTICE
    Never permit oil to get on the toric rings or ramps before both seal rings are put together in their final assembled position.

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    Illustration 42	g01585595

22. Use 1U-9977 Brush in order to apply a thin film of oil to the seal face.

    Note: In order to reduce the risk of airborne contaminants to the face of the seal. Minimize the time between the application of oil to the seal face and assembly of the collar on the retainer assembly.

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    Illustration 43	g01585596

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    Illustration 44	g01585597

23. Position the end collar on the shaft. Use the correct tooling and a hydraulic press in order to install the end collar. Refer to Table 13 for the correct tooling in order to install the end collar.

    Note: Approximately 22240 N (5000.0 lb) is required in order to install the end collar.

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    Table 13

    Tooling for End Collar
    Sales Model	Part Number
    D11T	170-5405
    D10T	170-5406

24. Repeat Step 23 in order to install the other end collar.
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    Illustration 45	g01585598

25. Use the correct spin socket to spin the shaft. Refer to table14 for the correct spin socket. The shaft should be spun 20 revolutions in each direction at a maximum of 100 rpm.
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    Table 14

    Spin Socket Tooling
    Sales Model	Part Number
    D11T	1U-3999
    D10T	FT-1909

26. Lubricate the circumference of the stopper with a light weight oil. Use the correct installer tool in order to install the stopper in the end of the shaft. Refer to table15 for the correct installer tool. The stopper must be installed 7 ± 7 mm (0.3 ± 0.3 inch) below the surface of the shaft.
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    Table 15

    Installer Tool Group
    Sales Model	Part Number
    D11T	228-0603
    D10T	228-0600

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    Illustration 46	g01585599

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    NOTICE
    Do not allow a surge of air to enter the idler and do not use pressure in excess of 138 kPa (20.0 psi), as this surge of air may damage the seals.

27. Use 170-5664 Test and Fill Cart Gp in order to evaluate and fill the idler.
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    Illustration 47	g01585600

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

    1. Introduce nitrogen into the oil cavity to a pressure of 138 kPa (20.0 psi).

    2. Turn the ball valve to the shutoff position.

    3. Close the pressure gauge.

    4. Observe the pressure for 10 seconds. A pressure drop 3.4 kPa (0.50 psi) or less is acceptable.

    5. Add the correct quantity of oil to the idler. Refer to Table 16 or Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for the oil volumes.
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       Table 16

       Sales Model	Oil Volumes	Recomended Oil
       D11T	1650 ± 80 mL (56.0 ± 3.0 oz)	Cat FDOA SYN oil
       D10T	825 ± 40 mL (28.0 ± 1.5 oz)

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       Table 17

       Cat FDAO Syn Part Numbers
       Liters
       18 L	208 L
       206-5211	206-5212
       Gallons
       5 gal	55 gal
       208-2390	198-7450

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    Illustration 48	g01585603

29. Use 5P-7419 Installer Tool in order to install the plug to the correct depth. The correct height of the plug is 0 mm to 5 mm (0.0 inch to 0.2 inch) above the surface of the stopper.

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

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    Illustration 49	g01585604

30. Gently tap the end of the idler shaft in order to determine if the idler contains oil. If the shaft thumps, the idler contains oil. The idler does not contain oil if there is a ring.

Installation of the Segments

Note: The true center line must be kept on all idler rebuilds for proper rebuild procedures. Measure from machined retainer surface on hub to establish the true center line of hub.

Illustration 50	g01573453
D11 bolt pattern

Illustration 51	g01573454
D10 bolt pattern

1. Apply 5P-3931 Anti-Seize Compound to the surfaces of the bars. Apply 5P-3931 Anti-Seize Compound to the threads of the bolts.
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   Illustration 52	g01571453

2. Position four segments (8) at the location of bars (7). Use a suitable driver in order to install bars (7).

   Note: Do not allow bars (7) to extend beyond the outer diameter of the idler.

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   Illustration 53	g01571493

3. Install the remaining segments.

   Note: Dimension (CC) should be equal between each of the segments.

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   Illustration 54	g01571554

4. Position two guides (6). Ensure that bars (7) are located between the bolt holes. Install the inner bolts and tighten the bolts hand tight.

   Bars (7) should be located between inner bolts (2) and (3) on the D11.

   Bars (7) should be located between inner bolts (1) on the D10.

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   Illustration 55	g01571595

5. Install remaining guides (6) and the inner bolts. Tighten the bolts hand tight.
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   Illustration 56	g01571613

6. Tighten the two inner bolts in order to install the outer bolts in guides (6). Tighten bolts hand tight.

   For the D11, install bolts (1), (4), and (5).

   For the D10, install bolts (2).

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   Illustration 57	g01576119

7. Position FT-3086 Table Base (B) on a level surface. Secure FT-3084 Adapter Plate (C) onto FT-3086 Table Base (B). Position Tooling (D) onto FT-3084 Adapter Plate (C), as shown.
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   Illustration 58	g01576123

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   Illustration 59	g01576125

8. Attach a suitable lifting device and 138-7573 Link Bracket (E) to the idler assembly.

9. Carefully position the idler assembly onto Tooling (D). Tooling (D) must contact the idler assembly, as shown.

   Note: Do not allow Tooling (D) to contact the segments or move beyond area (DD).

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   Illustration 60	g01576128

10. Position Tooling (F) onto the idler assembly. Attach a suitable lifting device to FT-3085 Hollow Square Bar (G). The weight of FT-3085 Hollow Square Bar (G) is approximately 68 kg (150.0 lb).

11. Position FT-3085 Hollow Square Bar (G) onto Tooling (F).
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    Illustration 61	g01576131

12. Use 9U-5344 Puller Studs (H), 8T-1583 Nuts (J), and 9X-8399 Washers (K) in order to secure FT-3085 Hollow Square Bar (G) to FT-3086 Table Base (B).
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    Illustration 62	g01576132

13. Use 6V-6080 Torque Multiplier Gp (L) and 8T-9293 Torque Wrench (M) in order to torque the bolts.

    Note: Applying the proper amount of torque to the bolts is critical. If excessive torque is exerted on the bolts, the rubber will be pushed out. If insufficient torque is applied to the bolts, the bolts may loosen during operation. Excessive segments shift and wear can result from improper seating of the segments.

    Note: Do not secure the idler by either the guides or the segments. The positioning of the guides and segments is critical to proper installation.

14. For the D11, use the following sequence in order to torque the bolts.

    1. Tighten bolt (1) through bolt (5) in sequence to a torque of 2300 ± 300 N·m (1696.0 ± 221.0 lb ft).

    2. Then, tighten bolt (1) through bolt (3) to a torque of 2300 ± 300 N·m (1696.0 ± 221.0 lb ft).

15. For the D10, use the following sequence in order to torque the bolts.

    1. Tighten bolts (1) to a torque of 2300 ± 300 N·m (1696.0 ± 221.0 lb ft). Tighten bolts (2) to a torque of 2300 ± 300 N·m (1696.0 ± 221.0 lb ft).

    2. Then, tighten bolts (1) to a torque of 2300 ± 300 N·m (1696.0 ± 221.0 lb ft).