Disassembly and Assembly Procedures for Idlers of D3K, D4K, and D5K Series Track Type Tractors {0374, 0599, 0729, 4159} Caterpillar

Track-Type Tractor

D3K (S/N: JTD1-UP; FFF1-UP; LLL1-UP)

D3K2 (S/N: KF21-UP; KL21-UP; FT31-UP; LT31-UP; GAE1-UP; KFF1-UP; JPJ1-UP; KLL1-UP)

D4K (S/N: MMM1-UP; RRR1-UP)

D4K2 (S/N: KM21-UP; KR21-UP; MT31-UP; RT31-UP; KMM1-UP; KRR1-UP)

D5K (S/N: JLF1-UP; WWW1-UP; YYY1-UP)

D5K2 (S/N: KW21-UP; KY21-UP; WT31-UP; YT31-UP; RRE1-UP; TRF1-UP; KWW1-UP; KYY1-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).

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Summary

The following information is given to provide Disassembly and Assembly procedures for idlers of (K) Series Track Type Tractors. During rebuild procedures, always correct any conditions which may have caused the original failure or wear.

References

Reference: Disassembly and Assembly of Front Idler and Track Adjuster - Remove and Install

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

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

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

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. A safety alert symbol like the one 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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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

Disassembly

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Note: The weight of the Idler Group is approximately 165.5 kg (364.86 lb).

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Illustration 2	g03839495

1. Remove Idler Group from Front Track Roller Frame.

   Reference: Disassembly and Assembly of Front Idler and Track Adjuster - Remove and Install

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   Illustration 3	g03839742

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   Illustration 4	g03839777

2. Reference Illustrations 3 and 4. Remove Hydraulic Track Adjuster by removing bolts (1) through (4).
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   Illustration 5	g03839782

3. Reference Illustration 5. Locate oil plug (5) on Idler. Remove plug (5) and drain oil.
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   Illustration 6	g03839958

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   Illustration 7	g03839948

4. Reference Illustrations 6 and 7. Locate Spring Pin (6) that retains Idler Bearing (7). Remove Spring Pin (6) with a hammer (A) and a punch (B) on one side of Idler.
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   Illustration 8	g03839988

5. Reference Illustration 8. Remove Idler Bearing (7) from Shaft (8) by using a Pry Bar (C).
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   Illustration 9	g03839994

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   Illustration 10	g03840011
   (8) Shaft (9) Duo-ConeSeal (10) Bearing Assembly (11) Track Bushing (12) O-ring

6. Once Idler Bearing (7) has no contact with O-ring (12) that is installed on Shaft (8), the Idler Bearing (7) can be removed by hand. Reference Illustration 9 and Illustration 10.
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   Illustration 11	g03840206

7. Remove Spring Pin (6) with a hammer (A) and a punch (B) on the other side of Idler. Reference Illustration 11.
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   Illustration 12	g03840237

8. Idler Bearing (7) and Shaft (8) will be attached by the O-ring (12) that is installed on Shaft (8). Remove Idler Bearing (7) and Shaft (8) reference Illustration 12.
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   Illustration 13	g03841788

9. Remove all Duo-Cone Seals (9) from Idler and Idler Bearing.
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   Illustration 14	g03841953

10. Using a suitable Vertical Hydraulic Shop Press align Tooling (D) with Shaft (8) that is attached to Idler Bearing (7).
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    Illustration 15	g03841978

11. Activate Hydraulic Shop Press. Use Tooling (D) to remove Shaft (8) from Idler Bearing (7).
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    Illustration 16	g03842552

12. Reference Illustration 16. Measure Bearing Assembly (10) dimensions (X), then reference Table 3 for correct dimensions. Determine if Bearing Assembly (10) can be reused.
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    Table 3

    Specifications for Bearing Assembly (10)
    Sales Model	Idler Group	Bearing Assembly (10)	Bearing Assembly (10) Bore Dimensions (X)
    D5K D5K2	422-2588	243-5321	54.3 ± 0.03 mm (2.14 ± 0.001 inch)
    D5K D5K2	419-5476	243-5321	54.3 ± 0.03 mm (2.14 ± 0.001 inch)
    D5K D4K D4K2 D3K D3K2	394-3645	236-4312	50.8 ± 0.08 mm (2.00 ± 0.003 inch)
    D5K D5K2 D4K D4K2 D3K D3K2	419-5475	236-4312	50.8 ± 0.08 mm (2.00 ± 0.003 inch)

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    Illustration 17	g03842553

13. Reference Illustration 17. Measure Shaft (8) dimension (Y), then reference Table 4 for correct dimensions. Determine if Shaft (8) can be reused.
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    Table 4

    Specifications for Shaft
    Sales Model	Idler Group	Shaft (8)	Shaft (8) Dimensions (Y)
    D5K D5K2	422-2588	254-0645	53.9 ± 0.025 mm (2.12 ± 0.001 inch)
    D5K D5K2	419-5476	254-0645	53.9 ± 0.025 mm (2.12 ± 0.001 inch)
    D5K D4K D4K2 D3K D3K2	394-3645	254-0644	50.4 ± 0.025 mm (2.00± 0.001 inch)
    D5K D5K2 D4K D4K2 D3K D3K2	419-5475	254-0644	50.4 ± 0.025 mm (2.00± 0.001 inch)

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    Illustration 18	g03842554

14. Reference Illustration 18. Measure Idler Bearing (7) Bore dimension (Z), then reference Table 5 for correct dimensions. Determine if Idler Bearing (7) can be reused.
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    Table 5

    Specifications for Idler Bearing
    Sales Model	Idler Group	Idler Bearing (7)	Idler Bearing (7) Bore Dimensions (Z)
    D5K D5K2	422-2588	389-1402	54.0 ± 0.05 mm (2.12 ± 0.002 inch)
    D5K D5K2	419-5476	389-1402	54.0 ± 0.05 mm (2.12 ± 0.002 inch)
    D5K D4K D4K2 D3K D3K2	394-3645	389-1401	50.5 ± 0.05 mm (2.00 ± 0.02 inch)
    D5K D5K2 D4K D4K2 D3K D3K2	419-5475	254-0634	50.5 ± 0.05 mm (2.00 ± 0.02 inch)

15. Reference Table 6 for Shaft (8) to Bearing (11) Clearance Dimensions.
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    Table 6

    Shaft (8) to Bearing (11) Clearance Dimensions
    Sales Model	Idler Group	Shaft (8) to Bearing (11) Clearance Dimensions
    D5K D5K2	422-2588	Maximum Clearance 0.4 mm (0.01 inch) Minimum Clearance 0.3 mm (0.01 inch)
    D5K D5K2	419-5476	Maximum Clearance 0.4 mm (0.01 inch) Minimum Clearance 0.3 mm (0.01 inch)
    D5K D4K D4K2 D3K D3K2	394-3645	Maximum Clearance 0.4 mm (0.01 inch) Minimum Clearance 0.2 mm (0.01 inch)
    D5K D5K2 D4K D4K2 D3K D3K2	419-5475	Maximum Clearance 0.4 mm (0.01 inch) Minimum Clearance 0.2 mm (0.01 inch)

16. Follow steps 17 through 21 if the Bearing Assembly (10) is to be removed from Idler.
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    Illustration 19	g03843117
    Straight Shaft Idler Bushing Removal Adapter Tool (E) Bolt Not Shown (F) Plate (G) Sleeve (H) Shaft (L) Complete Assembly Straight Shaft Idler Bushing Removal Adapter Tool

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    Illustration 20	g03860160

17. Straight Shaft Idler Bushing Removal Adapter Tool (L), maintains bushing quality (used for bushing removal of Idlers with Straight Shaft.)

    Reference Illustrations 19 and 20.

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    Illustration 21	g03862181

18. Assemble Straight Shaft Idler Bushing Removal Adapter Tool (L) inside the Idler and Bearing Assembly (10).

    Reference Illustration 21. Arrow indicates action of pressing tool to remove Bearing Assembly (10).

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    Illustration 22	g03843081

19. Illustration 22 displays the base of a Hydraulic Shop Press (D). The Idler and Bearing Assembly (10) has the assembled Straight Shaft Idler Bushing Removal Adapter Tool (L) inside the bore of the Bearing Assembly (10).
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    Illustration 23	g03843073

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    Illustration 24	g03843101

20. Reference Illustration 23 and Illustration 24. Tooling (D) will be activated removing Bearing Assembly (10) from the Idler bushing bore.

21. Repeat Steps 17 through 20 for the second Bearing Assembly (10) removal.
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    Illustration 25	g03848119

22. Reference Illustration 25. Use Tooling (D) and (E) to remove Bushing (11) from Bearing Assembly (10).
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    Illustration 26	g03849590

23. Place Tooling (E) in Bearing Assembly (10) and align with tooling (D), as shown in Illustration 26.
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    Illustration 27	g03849619

24. Reference Illustration 27. Activating Tooling (D) to remove Bushing (11) from Bearing Assembly (10).
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    Illustration 28	g03849634

25. Illustration 28 displays Bushing (11) that has been removed from Bearing Assembly (10).

26. Repeat Steps 22 through 25 for the removal of Bushing (11) for the other Bearing Assembly (10).

Assembly

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Illustration 29	g03849813

1. Mark the location of the holes in Bearing Assembly (10) and Bushing (11).

   Alignment of these holes during assembly is critical.

   Reference Illustration 29.

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   Illustration 30	g03850019

2. Clean with a lint free cloth and lubricate Bearing Assembly (10) and Bushing (11) with Tooling (F).

   Align the marked locations of the holes on Bearing Assembly (10) and Bushing (11).

   Reference Illustration 30.

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   Illustration 31	g03850054

3. Reference Illustration 31. Use Tooling (D) and (G) to install Bushing (11) into Bearing Assembly (10).
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   Illustration 32	g03850510

4. Illustration 32 displays Bushing (11) that is installed in Bearing Assembly (10).

5. Repeat Steps 1 through 4 for installation of Bushing (11) for the other Bearing Assembly (10).
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   Illustration 33	g03850559

6. Clean with a lint free cloth and lubricate the bushing bore of the Idler with Tooling (F).

7. Lower temperature of Bearing Assembly (10) for improved installation.
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   Illustration 34	g03850639

8. Reference Illustration 34. Use Tooling (D) and (G) to install Bearing Assembly (10) into Idler Bore.

   Activate Tooling (D) and install Bearing Assembly (10).

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   Illustration 35	g03850919

9. Illustration 35 displays the installed Bearing Assembly (10) and the Counterbore of the Idler.

10. Repeat Steps 6 through 9 for the installation of the other Bearing Assembly (10).

11. Prepare to Install Duo-Cone Seals (9) in the Counterbores of Idler and Bearing Assembly (10).

    The Counterbores should be clean, dry, and free of oil prior to Duo-Cone Seals (9) installation.

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    Table 7

    Part Numbers for Duo-Cone Seal Installer (H)
    Sales Model	Idler Group	Seal Installer (H)
    D5K D5K2	422-2588	9U-7537
    D5K D5K2	419-5476	9U-7537
    D5K D4K D4K2 D3K D3K2	394-3645	1U-8850
    D5K D5K2 D4K D4K2 D3K D3K2	419-5475	1U-8850

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    Illustration 36	g03856023

12. Ensure the Duo-Cone Seals (9) are free of contamination. Install the Duo-Cone Seals (9) in Seal Installer (H). Reference Table 7 for the correct Seal Installer (H).
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    Illustration 37	g03856651

13. Place a small amount of Isopropyl Alcohol (M) on bottom of Toric Ring of Duo-Cone Seal (9).

    Isopropyl Alcohol (M) acts as a lubricant and will leave no residue after evaporating.

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    Illustration 38	g03857051

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    Illustration 39	g03856687

14. Install Duo-Cone Seal (9) in Counterbore of Idler.
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    Illustration 40	g03857205

15. Illustration 40 displays the Duo-Cone Seal (9) installed in the Idler.
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    Illustration 41	g03857213

16. Reference Illustration 41. Use Dial Caliper (K) to measure height of Duo-Cone Seal (9) in four 90 degree locations.

    The difference in height must not exceed 1.0 mm (0.04 inch). If assembled height does not meet specifications, the Duo-Cone Seal (9) will need to be reinstalled.

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    Illustration 42	g03857722

17. Repeat Steps 11 through 14 for the installation of the Duo-Cone Seals (9) for the Idler Bearings (7). Reference Illustration 42.
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    Illustration 43	g03857812

18. Reference Illustration 43. Apply Grease-PetroGel (J) to new O-ring (12) to install new O-ring (12) onto one side of shaft .
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    Illustration 44	g03857838

19. Press Shaft (8) into Idler Bearing (7). Align Spring Pin Bores in both Shaft (8) and Idler Bearing (7). Reference Illustration 44.
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    Illustration 45	g03857871

20. Align Spring Pin Bores and Insert Spring Pin (6).
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    Illustration 46	g03857881

21. Install Spring Pin (6) to a depth of 3.7 mm (0.15 inch) into Spring Pin Bores in Idler Bearing (7) and Shaft (8) with Hammer (A). Reference Illustration 46.
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    Illustration 47	g03857960

22. Prior to assembly wipe off Duo-Cone Seals (9) with a lint free cloth.

    Then apply Oil (F) to sealing surface of all Duo-Cone Seals (9).

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    Illustration 48	g03857968

23. Reference Illustration 48. Lubricate shaft (8) and Bearing Assembly (10).

    Install Idler Bearing (7) and Shaft (8) into Bearing Assembly.

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    Illustration 49	g03857970

24. Apply Grease-Petro Gel (J) to new O-ring (12) and install new O-ring (12) onto one side of Shaft (8). Reference Illustration 49.
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    Illustration 50	g03857974

25. Mark the orientation of Spring Pin Bores on Shaft (8) and Idler Bearing (7) for proper alignment.
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    Illustration 51	g03858007

26. Press Idler Bearing (7) onto Shaft (8).
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    Illustration 52	g03858002

27. The marks for the Spring Bores on Shaft (8) and Idler Bearing (7) should be aligned.
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    Illustration 53	g03858008

28. Install Spring Pin (6) to a depth of 3.7 mm (0.15 inch) into Spring Pin Bores in Idler Bearing (7) and Shaft (8) with Hammer (A). Reference Illustration 46.

29. Reference Table 8 for Oil Fill Volumes per Idler Group.
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    Table 8

    Oil Fill Volumes
    Sales Model	Idler Group	Oil Volume	Oil
    D5K D5K2	422-2588	0.4 ± 0.02 L (0.10 ± 0.005 US gal)	8C-3698
    D5K D5K2	419-5476
    D5K D4K D4K2 D3K D3K2	394-3645	0.17 ± 0.02 L (0.045 ± 0.005 US gal)
    D5K D5K2 D4K D4K2 D3K D3K2	419-5475

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    Illustration 54	g03858522

30. Install oil plug (5).
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    Illustration 55	g03839742

31. Use 5P-3931 Anti-Seize Compound on Bolt Threads.

    Torque Bolts 1 through 4 for Hydraulic Track Adjuster to the specifications in Table 9.

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    Table 9

    Bolt Torque Values for Hydraulic Track Adjuster
    Sales Model	Bolt Size	Bolt Torque Value
    D5K D5K2 D4K D4K2 D3K D3K2	(M12 X 1.75)	100.0 ± 20.0 N·m (73.75 ± 14.75 lb ft)