Guideline for Roller and Idler Component Reuse {4159, 4180} Caterpillar

Caterpillar Products

Machines with Grease Lubricated Track with Swage

Machines with Greased Lubricated Track (GLT)

Machines with Positive Pin Retention (PPR) Track

Machines with Positive Pin Retention 2 (PPR2) Track

Machines with Rotating Bushing Track

Machines with Sealed Positive Pin Retention (PPR) Track

Machines with Sealed Track

Machines with Sleeve Bearing Track

Machines with SystemOne Undercarriage

Machines with non-PPR Sealed and Lubricated Track

Track Drills

MD5150C (S/N: SEY1-UP)

Introduction

© 2019 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 bulletin enables dealers and customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current and relevant information known to Caterpillar Inc. Caterpillar makes ongoing changes and improvements to Caterpillar products. This bulletin must be used with the latest technical information available from Caterpillar to ensure that such changes and improvements are incorporated where applicable.

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

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Summary

The following information is given to provide procedures for idler and track roller bearing removal, installation, and conditioning. The roll-burnishing process and the piloted hone process bearing conditioning methods are covered. Both procedures ensure the proper bearing finish (particularly in the clinch joint area), and the correct bearing alignment. Idlers are pictured throughout this bulletin for simplicity.

References

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8584, "Disassembly and Assembly Procedures for Track Rollers with Conventional Duo-Cone Seals"

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

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8597, "Reconditioning Procedure for Seal Ramps on Inverted Style Idler and Roller Shafts"

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8581, "Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-Cone Seals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8588, "Oval Track Roller Disassembly and Assembly Procedures"

Reference: Undercarriage Reconditioning Bulletin, SEBF8552, "Idler Weld Rebuild Procedure"

Reference: Refer to Undercarriage Reconditioning Bulletin, SEBF8571, "Reconditioning Dimensions for Idlers"

Safety

Illustration 1	g03399806

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

Illustration 2	g02046813
(1) 5P-1720 Seal Pick

Illustration 3	g02046837
(2) Bearing surfaces

Note: Shafts should be inspected for reusability. Tooling 5P-1720 Seal Pick can be used to evaluate the bearing surface of the shaft, refer to Illustration 2 and Illustration 3. Surface damage that can be detected with the tool indicates that the shaft should not be reused.

Use again

Use the shaft again if the shaft has:

• No scratches

• No pitting

• No galling on the thrust washer surface

• No galling on the bearing surface

Illustration 4	g02046879
(3) Thrust washer surface. No galling, pitting, or scratches allowed on thrust washer surface.

Illustration 5	g02046913
(4) Inverted Duo-Cone seal ramp area (reusable)

The toric of the Inverted Duo-Cone rides on the seal ramp of the shaft. To be reuseable, the shaft seal ramp must have a roughness of Ra 5.0 µm to 8.75 µm.

A 9A-1593 Comparison Gauge can be used to evaluate the surface texture of the seal ramp. Row H can be used as a guide for the minimum roughness.

Use again.

Reuse shaft for Inverted Duo-Cone seal when seal ramp has proper roughness. Refer to Illustration 5

Illustration 6	g02046914
(5) Inverted Duo-Cone seal ramp area damaged (not reusable)

Do not use again.

Do not reuse shaft for Inverted Duo-Cone seal when ramp areas that are smooth, rusted, pitted, or grooved. Refer to Illustration 6.

Illustration 7	g02046958

Use again.

Reuse retainer if lip thickness is at least 2.0 mm (0.08 inch). Refer to Illustration 7.

Illustration 8	g02047117
(7) Thrust washer

Use again.

Reuse thrust washer if:

• The roller had oil.

• The roller did not leak.

• The thrust washer is not heavily worn, scratched, or dented.

Illustration 9	g02047635
(8) Thrust washer

Do not use again.

Do not reuse thrust washer with pitting. Refer to Illustration 9.

Do not use again.

Do not reuse worn thrust washer that has no oil grooves.

Illustration 10	g02047801
Fixed thrust washer

Use again.

Reuse thrust washers that are fixed to the retainer by pins, if:

• The pins do not protrude past the thrust washer.

• The pins securely hold the thrust washer to the retainer.

• The pins are not worn or scratched.

Illustration 11	g02049300
(B) Shaft to bearing clearance (9) Bearing (10) Shaft (11) Idler

Bearings should be checked for the proper bearing to shaft clearance. The shaft to bearing clearance depends on the condition of the bearing and the bore that the bearing is installed.

Do not use again.

Do not reuse bearings poorly lubricated during operation.

Roller and idler bearing specifications can be found in the following documents:

Refer to Undercarriage Reconditioning Guide, SEBF8599 for the following documents:

• Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations forDuo-Cone Seals",

• Undercarriage Reconditioning Bulletin, SEBF8584, "Disassembly and Assembly Procedures for Track Rollers with ConventionalDuo-Cone Seals",

• Undercarriage Reconditioning Bulletin, SEBF8585, "Disassembly and Assembly Procedures for Idlers with ConventionalDuo-Cone Seals"

• Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals"

• Undercarriage Reconditioning Bulletin, SEBF8581, "Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-Cone Seals"

Illustration 12	g02049314
(12) Bearing seating surface

Do not use again.

Do not reuse bearings if there is any evidence of:

• Embedded debris

• Grooved

• Scratched

• Moved (walked)

• Discolored

Use again.

Bearings that are smooth with minimal hatch marks.

Bearings with no signs of scratching and properly aligned in bore.

Note: Replace all rubber components with new components.

Use the Tooling 5P-1720 Seal Pick to inspect the shaft for reusability.

Do not use again.

Do not reuse shafts with:

• Pitting.

• Galling on thrust washer surface.

• Galling on bearing surface.

Illustration 13	g02049816
(13) Bearing surfaces

Illustration 14	g02049875
(14) Thrust washer surface on Conventional Duo-Cone seal shaft

Illustration 15	g02046934
(6) Visible clearance between non-abutment side of cap and track roller frame.

Use again.

Idler or roller shaft stub end diameter acceptable if:

• The cap is assembled to the roller frame.

• There is a visible clearance between the non-abutment side of the cap and the roller frame. Refer to Illustration 15.

Note: The visible clearance gives proper clamping force on the shaft stub end.

Illustration 16	g02049933
Measuring Conventional Duo-Coneseal collar for specification

Illustration 17	g02049993
Collar cross section view C-C (Ra) Roughness value should be with in Ra 3.75 µm to 8.75 µm

Additional Criteria:

• The seal ramp for the collars, which the toric for the Conventional Duo-Cone seal rides on, must have a roughness of Ra 3.75 µm to 8.75 µm to be reused.

• Do not reuse a collar if the seal ramp areas are smooth, rusted, pitted, or grooved.

• Use tooling 9A-1593 Comparison Gauge to evaluate the surface texture of the seal ramp in the collar.

• Use the turn, face, or bore cast iron or steel column and the F row to determine reusability.

• The texture gauge is used to indicate the appropriate surface texture. Evaluate the roughness by touch.

Illustration 18	g02050057
Tooling 9A-1593 Surface Texture Comparison gauge.

Illustration 19	g02050273
(15) Thrust washer

Use again.

Reuse thrust washers if:

• The roller had oil.

• The roller did not leak.

• The thrust washer is not heavily worn, scratched, or dented.

Illustration 20	g02047635
(8) Thrust ring

Do not use again.

Do not reuse thrust ring with pitting. Refer to Illustration 20.

Do not reuse worn thrust ring that has no oil grooves.

Use again.

Reuse thrust rings that are fixed to the retainer by pins if:

• The pins do not protrude past the thrust ring.

• The pins securely hold the thrust ring to the retainer.

• The pins are not worn or scratched.

Illustration 21	g02050294
Fixed thrust washer

Refer to Illustration 21 for a thrust washer that is attached to the retainer.

Illustration 22	g02049300
(B) Shaft to bearing clearance (9) Bearing (10) Shaft (11) Idler

• Do not reuse bearings not been sufficiently lubricated.

• Bearings should be checked for the proper bearing to shaft clearance.

• Shaft to bearing clearance depends on the condition of the bearing and the bore that the bearing is installed.

• Bearing dimensions may be checked by subtracting the shaft diameter (outside) from the installed bearing diameter (inside).

• A feeler gauge can also be used to check the shaft to bearing end play.

Do not use again.

Do not reuse bearings with evidence of the following:

• Embedded debris

• Grooved

• Scratched

• Moved (walked)

• Discolored

Use again.

Reuse bearings:

• Which are smooth with minimal hatch marks.

• With no signs of scratching.

• Properly aligned in bore.

Idler shell

• Wear limits

• To allow for reuse, the idler shell must not exceed certain wear limits. The dimensions for the bore can be found in the Undercarriage Reconditioning Bulletin, SEBF8571, "Reconditioning Dimensions for Idlers"

• The wear limits for the outside diameter of the idler shell can be found in the Custom Track Service handbook, PEKP9400. Idlers exceeding 100% wear should not be rebuilt.

Illustration 23	g02053228
Welding restraints and wear limits (D) 100% wear (E) Tread thickness (F, G, or H) Cracks cannot be weld repaired in these regions.

Examine the idler shell for cracks. Refer to Illustration 1 for idler regions. If cracks appear in regions F, G, or H, the crack cannot be weld repaired. Cracks in other regions can be repaired with welding.

Evaluate the condition of the idler.

Refer to Undercarriage Reconditioning Bulletin, SEBF8571, "Reconditioning Dimensions for Idlers" for specifications for the following:

• Installed bearing diameter

• Center flange width

• Tread width

• Flange to tread radius

• Tread diameter

• Center flange diameter

• 100% worn dimension

• Tread face to hub face

• Idler hub diameter