Repair Procedure for Retainer Assemblies on Track Idlers and Rollers {4159, 4180} Caterpillar

Pipelayer

561H (S/N: 6NL1-UP)

572R (S/N: AAC1-UP; 2HZ1-UP)

572R Series II (S/N: DSC1-UP)

578 (S/N: 8HB1-UP)

583R (S/N: 2XS1-UP)

589 (S/N: 31Z1-UP)

Track-Type Loader

939 (S/N: 9GL1-UP)

943 (S/N: 03Y1-UP; 31Y1-UP; 04Z1-UP; 19Z1-UP)

953 (S/N: 76Y1-UP; 77Y1-UP; 78Y1-UP; 05Z1-UP; 20Z1-UP; 44Z1-UP)

963 (S/N: 29S1-UP; 06Z1-UP; 11Z1-UP; 18Z1-UP; 21Z1-UP; 48Z1-UP)

973 (S/N: 66G1-UP; 86G1-UP; 90L1-UP; 91L1-UP; 26Z1-UP; 32Z1-UP)

Track-Type Skidder

527 (S/N: 2RS1-UP; 3DS1-UP; 4NS1-UP; BDW1-UP)

Track-Type Tractor

D10 (S/N: 84W1-UP; 76X1-UP)

D10N (S/N: 2YD1-UP)

D10R (S/N: 3KR1-UP; AKT1-UP)

D10T (S/N: RJG1-UP)

D11N (S/N: 4HK1-UP; 74Z1-UP)

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

D11T (S/N: RAL1-UP)

D4H (S/N: 8PB1-UP; 9DB1-UP; 2AC1-UP; 3AC1-UP)

D5H (S/N: 7NC1-UP; 8RC1-UP; 9HC1-UP; 1DD1-UP; 1YD1-UP; 2SD1-UP; 3MD1-UP; 4KD1-UP)

D6H (S/N: 8KB1-UP; 4RC1-UP; 6FC1-UP; 7PC1-UP; 8FC1-UP; 8YC1-UP; 3ZF1-UP; 3YG1-UP; 1FJ1-UP)

D6H Series II (S/N: 1KD1-UP; 2KD1-UP; 3ED1-UP; 4YF1-UP; 2TG1-UP; 4GG1-UP; 4LG1-UP)

D6M (S/N: 9ZM1-UP; 2RN1-UP; 3WN1-UP; 4JN1-UP; 5NR1-UP; 5WR1-UP; 6LR1-UP; 2YS1-UP; 4GS1-UP; 4HS1-UP)

D6N (S/N: CBF1-UP; CCG1-UP; ALH1-UP; CBJ1-UP; CCK1-UP; AKM1-UP; ALR1-UP; CCS1-UP; ALY1-UP)

D6R (S/N: 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP)

D6R Series II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D7H (S/N: 2SB1-UP; 4AB1-UP; 5WB1-UP; 5BF1-UP; 2RG1-UP; 3XG1-UP; 4FG1-UP; 77Z1-UP; 79Z1-UP; 80Z1-UP; 82Z1-UP)

D7R (S/N: BPK1-UP; BNM1-UP; BRM1-UP; 9HM1-UP; 2EN1-UP; 3DN1-UP; BRP1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; BPT1-UP; BNX1-UP)

D7R Series II (S/N: AEC1-UP; AFG1-UP; ABJ1-UP; AGN1-UP; ACS1-UP; ADW1-UP)

D8L (S/N: 4FB1-UP; 7YB1-UP; 7JC1-UP; 53Y1-UP)

D8N (S/N: 9TC1-UP)

D8R (S/N: 7XM1-UP; 9EM1-UP; 6YZ1-UP)

D8R Series II (S/N: AKA1-UP)

D8T (S/N: KPZ1-UP)

D9L (S/N: 14Y1-UP)

D9N (S/N: 1JD1-UP)

D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

D9T (S/N: RJS1-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 in order 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 in order 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 or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

Summary

This bulletin provides the steps, required tooling, and parts necessary to repair retainer assemblies on track idlers and rollers. The repair is performed by attaching a new thrust washer on a former retainer with dowels.

Do not perform repairs until becoming familiar with the information in this bulletin.

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. Hazardous steps will be identified by warning symbols like the one 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.

Illustration 2	g03186216
Example warning

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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.

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 and Parts

Illustration 3	g01194886
(1) 6D-5356 Knob (2) 8D-8815 Stud (3) 7F-7237 Spring (4) FT-1918 Base Plate (5) Drill Fixture

Repair Procedure

Illustration 4	g01177053
(A) Holes for the dowels

1. Remove the idlers and/or rollers and remove the retainer assembly. See the Service Manual for the correct procedure.
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   Illustration 5	g01195863

2. Remove the damaged thrust washer from the retainer assembly.
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   Illustration 6	g01176093

3. Remove the protrusions from the former retainer with a die grinder and grinding wheel.

   Note: Use a small grinding wheel to prevent the removal of excessive plate material.

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   Illustration 7	g01194882

4. Remove any remaining roughness from the retainer with a flat file.
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   Illustration 8	g01195871

5. Use a straightedge on the retainer and the thrust washer to make sure that all the protrusions have been removed.

6. Wipe the thrust washer and mating surfaces of the retainer with a clean cloth.
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   Illustration 9	g01194900

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   Illustration 10	g01194902

7. Assemble the thrust washer and the retainer in the drill fixture.
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   Illustration 11	g01195902
   (B) Channels for lubrication (C) Holes of drill fixture

8. Align the holes of drill fixture (C) between channels for lubrication (B) in the thrust washer.
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   Illustration 12	g01196031

9. Use the drill fixture as a guide. Mark the holes for drilling with a transfer punch in the four holes on the drill fixture.

   • Use a 4.8 mm (0.19 inch) transfer punch on retainers with 8H-4952 Dowels, 190-6055 Dowels, or 2H-1190 Dowels.

   • Use a 3.2 mm (0.13 inch) transfer punch on retainers with 1L-5072 Dowels.
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   Illustration 13	g01196034
   (D) Marks from the transfer punch

10. Loosen the drill fixture. Rotate the drill fixture in order to allow the marked holes to be drilled.

    Note: Only turn the drill fixture. Rotating the thrust washer may result in drilling into the former holes on the retainer.

11. Tighten the drill fixture in order to hold the thrust washer in place.
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    Illustration 14	g01196038

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    Illustration 15	g01196040

12. Drill and ream the four holes. Refer to Table 4 for the correct size of drill bit.

    Note: The depth of the hole should be equal to the length of the dowel. The depth includes the thrust washer and the retainer.

    Note: An interference fit of 0.05 mm (0.002 inch) is required. Refer to the final hole sizes in Table 5 in order to select the correct drill and the correct reamer.

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    Table 4

    Drill Size
    Dowel	Letter Designation	Dimension
    8H-4952	D	6.248 mm (0.246 inch)
    190-6055 2H-1190	C	6.147 mm (0.242 inch)
    1L-5072	--	4.60 mm (0.181 inch)

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    Table 5

    Dimensions of the Dowel Holes
    Dowel	Final Hole Size
    8H-4952	6.327 mm (0.2491 inch) diameter
    190-6055 2H-1190	6.165 mm (0.2427 inch) diameter
    1L-5072	4.577 mm (0.1802 inch) diameter

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    Illustration 16	g01196160

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    Illustration 17	g01196163

13. Drill a chamfer on the thrust washer in order to create a countersunk hole in the thrust washer.

14. Use a hammer with a soft tip to drive the dowels through the thrust washer and into the retainer holes. Remove the retainer assembly from the drill fixture.
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    Illustration 18	g01196472

15. Drive the dowels into the retainer assembly until the dowels hit the bottom of the hole.
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    Illustration 19	g01196478

16. Use a punch in order to create a mushroomed end on the dowel.
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    Illustration 20	g01196516

17. Remove any remaining protrusions on the thrust washer with a flat file.
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    Illustration 21	g01196519

18. Use a straightedge to make sure that all protrusions have been removed.
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    Illustration 22	g01196522
    Acceptable

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    Illustration 23	g01196526
    Unacceptable

19. With a feeler gauge, check for a gap between the thrust washer and the retainer. No gap is preferred, but a maximum gap of 0.08 mm (0.003 inch) is acceptable.

    Note: This step ensures the correct internal clearance after a roller or an idler has been assembled.

20. Clean the retainer in a wash tank.

21. Assemble the retainer assembly on the roller or the idler.
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    Illustration 24	g01196671

22. Measure the end play after assembly. Refer to the following tables below for the correct end play.