572R Pipelayer Power Train Caterpillar

Idler - Assemble

Usage:

572R 2HZ

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	8T-939	Seal Installer	1
B	8T-822	Alignment Sleeve	1
C	5P-7419	Plug Installer	1
D	FT-575	Test Tool	1
E	8S-2328	Dial Indicator	1

Clean all the parts. Inspect the parts for wear or for damage. Replace any parts that are worn or damaged.

Be certain that all the parts are free of oil, dust, or other foreign material. Use Isopropyl alcohol and a clean cloth to clean the parts.

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Illustration 1	g00617057

Note: The bearing in idler assembly (1) can be damaged when shaft (2) is installed in the idler.

Fasten a suitable lifting device to shaft (2). Carefully put shaft (2) in the correct position in idler assembly (1) .

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Illustration 2	g00617060

Put toric stabilizers (3) in the correct position on both ends of shaft (2) .

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Illustration 3	g00617062

Note: Before the installation of any Duo-cone seals, refer to Disassembly and Assembly, "Duo-Cone Floating Seals - Install" for the correct procedure.

Put toric ring (4) in the correct position in seal ring (5). Be certain that the toric ring is straight in seal ring (5) .

Put toric ring (4) and seal ring (5) in Isopropyl alcohol until the entire toric ring is wet.

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Illustration 4	g00617066

Use Tooling (A) to install the toric ring and seal ring (5) on shaft (2). Install the rings until Tooling (A) contacts the end of shaft (2) .

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Illustration 5	g00617070

Use depth micrometer (6) to measure the distance between seal ring (5) and the shaft. Measure the distance at four points that are separated by 90 degrees. The difference in the measurements must not exceed 0.80 mm (0.032 inch).

If seal ring (5) must be adjusted, use Tooling (A) to adjust the seal ring on the shaft.

Repeat Step 5 through Step 9 in order to install the toric ring and the seal ring on the other side of the idler.

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Illustration 6	g00617072

Put O-ring seal (8) in the correct position on seal ring (7). Be certain that the O-ring seal is straight on the seal ring.

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Illustration 7	g00617074

Lubricate the O-ring seal on the seal ring with Isopropyl alcohol.

Put the O-ring seal and seal ring (7) in the correct position on retainer (9). Use Tooling (A) and a hydraulic press to install the seal ring in the retainer. Install the O-ring seal and the seal ring until the O-ring seal contacts the bottom of the retainer.

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Illustration 8	g00617083

Use depth micrometer (6) to measure the distance from the surface of retainer (9) to the surface of seal ring (7). Measure the distance at four locations that are separated by 90 degrees. The difference in the measurements must not exceed 0.30 mm (0.012 inch).

If the seals must be adjusted, use Tooling (A) to adjust the seal ring in the retainer.

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Illustration 9	g00617085

Put O-ring seal (10) in the correct position in the groove in retainer (9) .

Put Vaseline or grease on O-ring seal (10) in order to install the seal on the retainer.

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Illustration 10	g00617087

Install washer (11) on the end of shaft (2) .

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Illustration 11	g00617088

Be certain that the faces of the rings are free of any foreign material.

Put a thin film of clean oil on the faces of the seal rings.

Put Tooling (B) in the correct position in the bores of retainer (9) and the seal ring. Use Tooling (B) to install the seal ring and retainer (9) in the original position on the idler assembly.

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Illustration 12	g00617096

Use Tooling (B) to hold the seal ring and retainer (9) in the correct position on the idler assembly.

Install bolts (12). Evenly tighten the bolts so that retainer (9) remains aligned with the idler assembly.

Tighten bolts (12) to a final torque of 70 ± 15 N·m (51.6 ± 11.1 lb ft).

Repeat Step 11 through Step 24 in order to install the retainer on the other side of the idler.

Use Tooling (D) to test the pressure of the idler assembly in the following manner:
1. Put air that is free of water in the idler shaft at a pressure of 280 kPa (40.6 psi).
1. If there is a pressure reduction in ten seconds or less, there is a leak in the idler assembly. Disassemble the idler assembly and then check the idler assembly.

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Illustration 13	g00617097

Use Tooling (E) to check the end play of shaft (2). The end play must be 0.25 mm (0.009 inch) to 0.85 mm (0.034 inch).

Fill idler shaft (2) with 6.5 ± .15 L (1.717 ± 0.039 US gal) of oil.

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Illustration 14	g00617098

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Illustration 15	g00617099

Put clean oil on stopper (13). Install the stopper in the end of shaft (2). Install the stopper until the stopper is below the surface of the shaft end by 10 ± 4 mm (0.4 ± 0.2 inch).