Disassembly and Assembly Procedures for Landfill Idlers {4159} Caterpillar


Disassembly and Assembly Procedures for Landfill Idlers {4159}

Usage:

D6R 1RW
Track-Type Tractor
D10R (S/N: 3KR1-UP; AKT1-UP)
D10T (S/N: RJG1-UP)
D6H (S/N: 8KB1-UP; 4RC1-UP; 6FC1-UP; 3ZF1-UP; 5HF1-UP; 6CF1-UP; 3YG1-UP)
D6H Series II (S/N: 8ZJ1-UP; 9KJ1-UP; 5KK1-UP; 6CK1-UP; 1YL1-UP; 2BL1-UP)
D6N (S/N: MG51-UP; GB61-UP; PBA1-UP; LJR1-UP; PER1-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; DMP1-UP; 4JR1-UP; 4TR1-UP; 6FR1-UP; 6MR1-UP; 7GR1-UP; 9ZS1-UP; S6T1-UP; 1RW1-UP; S6X1-UP; S6Y1-UP)
D6R Series II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BLE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP)
D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; LGP1-UP; MRT1-UP)
D6R2 (S/N: PPP1-UP; SSS1-UP; TTT1-UP)
D6T (S/N: JHB1-UP; KSB1-UP; ZEB1-UP; ZJB1-UP; JZC1-UP; SMC1-UP; DTD1-UP; JWD1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; KJL1-UP; SKL1-UP; TSM1-UP; WLM1-UP; PLR1-UP; GCT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; PEZ1-UP)
D7E (S/N: TJA1-UP; MDB1-UP; SCG1-UP; TAN1-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: DSH1-UP; BPK1-UP; BNM1-UP; BRM1-UP; 9HM1-UP; DLN1-UP; 2EN1-UP; 3DN1-UP; DJR1-UP; 2HR1-UP; 3ZR1-UP; 5MR1-UP; BPT1-UP; BNX1-UP; CBZ1-UP; 5KZ1-UP)
D7R Series II (S/N: EEA1-UP; KNA1-UP; AEC1-UP; AFG1-UP; ABJ1-UP; AGN1-UP; ACS1-UP; ADW1-UP)
D8R (S/N: 7XM1-UP; 9EM1-UP; 6YZ1-UP)
D8R Series II (S/N: AKA1-UP)
D8T (S/N: J8B1-UP; MLN1-UP; FCT1-UP; KPZ1-UP)
D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)
D9T (S/N: TWG1-UP; RJS1-UP)

Introduction

Table 1
Summary of Changes in SEBF8616 
Revision  Description 
12  Added serial number prefixes for New Product Introduction. 
11  Added serial number prefixes for New Product Introduction. 
10  Added serial number prefixes for New Product Introduction. 
09  Added D6R2 to tables.
Added serial number prefixes for New Product Introduction. 
08  Added serial number prefixes for New Product 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 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 or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

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

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface

Summary

This guideline provides the Disassembly and Assembly information for landfill idlers. These idlers have an extra plate on the retainer to aid in keeping debris out of the Duo-Cone seal. The rope seal that was previously used for landfill applications has been eliminated. The rope seal should be removed on idlers that are being rebuilt. New idlers do not have the groove in the retainer for the rope seal.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599, "Undercarriage Reconditioning Guide Binder (Subscription 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: 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 1g02139237

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.

------ WARNING! ------

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.


------ WARNING! ------

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.


------ WARNING! ------

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 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

Table 2
Required Tools 
Part Number  Description 
8T-0447  Dial Caliper As 
8T-5096  Dial Indicator Test Group 
369-9450  Grease Petro Gel
O-Ring Assembly Compound 
170-5664  Test and Fill Cart Gp 
FT-2724  Pressure Gauge Tool Gp 
Loctite® C5-A®  Copper-based Anti-Seize Lubricant 
1U-9977  Brush 
5P-7419  Installer Plug 
8H-8581  Gage-Feeler 
162-5791  Towel-Shop 
265-2256  Wipers 
228-0600(1)  Installer GP-Stopper 
228-0597(2)  Installer GP-Stopper 
129-1340(3)  Seal Installer Assembly 
227-4755(4)  Seal Installer Assembly 
224-9467(5)  Seal Installer Assembly 
FT1909(3)  Spin Socket 
FT1910(4)  Spin Socket 
FT1911(5)  Spin Socket 
170-5406(3)  Driver/ Tooling for End Collar 
170-5409(6)  Driver/ Tooling for End Collar 
170-5408(7)  Driver/ Tooling for End Collar 
170-5411(8)  Driver/ Tooling for End Collar 
170-5412(9)  Driver/ Tooling for End Collar 
(1) Idlers with 9G-4872 Stoppers, D10N, D10R, D10T, D9N, D9R, D9T, D8N, D8R, D8T
(2) Idlers with 9G-5664 Stoppers, D7E, D7H, D7R, D6H, D6R, D6R2, D6T
(3) D10N, D10R, D10T
(4) D9N, D9R, D9T, D8N, D8R, D8T
(5) D7E, D7H, D7R, D6H, D6R, D6R2, D6T
(6) D9N, D9R, D9T
(7) D8N, D8R, D8T
(8) D7E, D7H, D7R
(9) D6H, D6R, D6R2, D6T

Disassembly of Idlers with Conventional Duo-Cone Seals



Illustration 2g01257575
(1) Retainer
(2) Plate
(3) Collar
(4) O-Ring on the collar
(5) Duo-Cone seal group
(6) Retainer bolt


    Illustration 3g02102144

  1. Remove the plastic plug and the rubber stopper from the end of the shaft to drain the oil.


    Illustration 4g01259134

  2. Remove bolts (6) from the plate and the retainer on both sides of the idler.

  3. Remove plates (2) from both sides of the idler.

  4. Use a hydraulic press to remove the collars from both sides of the idler.

    Note: Use approximately 22240 N (5000 lb) to 66720 N (15000 lb) to remove the collar.

  5. Remove retainer (1) and the thrust washers from both sides of the idler.

    Note: Thrust washers may be pinned on the retainer assembly. Refer to Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers" to remove the thrust washer from the retainer.



    Illustration 5g01531253


    Illustration 6g02183514

  6. Use 8T-0447 Dial Caliper to measure inside diameter (AA) of the end collar and shaft diameter (BB). Refer to Table 3 and Table 4 for the correct dimensions. Replace the components if the components are not within specifications.

    Table 3
    Specifications for the End Collar 
    Sales Model  Part Number of the End Collar  Inner Diameter
    (AA) 
    D10N
    D10R
    D10T 
    261-9674  74.4 ± 0.02 mm (2.93 ± 0.001 inch) 
    D9N
    D9R
    D9T
    D8N
    D8R
    D8T 
    261-9673  68.4 ± 0.02 mm (2.70 ± 0.001 inch) 
    D7E
    D7H
    D7R 
    166-3317  58.4 ± 0.02 mm (2.30 ± 0.001 inch) 
    D6H
    D6R
    D6R2
    D6T 
    167-1951  58.4 ± 0.02 mm (2.30 ± 0.001 inch) 
    D6N  189-2170  46.4 mm ± 0.02 mm (1.827 inch ± 0.001) 

    Table 4
    Specifications for the Shaft 
    Sales Model  Part Number of the Shaft  Diameter
    (BB) 
    D10N
    D10R
    D10T 
    154-3308  74.5 ± 0.02 mm (2.93 ± 0.001 inch) 
    D9N
    D9R
    D9T 
    154-3309  68.5 ± 0.02 mm (2.70 ± 0.001 inch) 
    D8N
    D8R
    D8T 
    154-3307  68.5 ± 0.02 mm (2.70 ± 0.001 inch) 
    D7E  351-8927  58.5 ± 0.02 mm (2.30 ± 0.001 inch) 
    D7H
    D7R 
    131-3935  58.5 ± 0.02 mm (2.30 ± 0.001 inch) 
    D6H
    D6R
    D6R2
    D6T 
    149-2494  58.5 ± 0.02 mm (2.30 ± 0.001 inch) 
    D6N  161-7350  46.5 ± 0.02 mm (1.83071 ± 0.001 inch) 


    Illustration 7g01257852

  7. Clean the old rope seal out of the retainer. Removal of the rope seal may be difficult if the seal is not in good condition.

    Note: The rope seal is located in the plate on D7 idlers. Refer to Illustration 2.



    Illustration 8g01257854

  8. Remove the large O-ring seals from each retainer assembly.


    Illustration 9g01257865

  9. Remove the O-rings from each end collar assembly.


    Illustration 10g01579126


    Illustration 11g01257867

  10. Remove the Duo-Cone seals from the retainer and end collar assemblies.

  11. 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.



    Illustration 12g01257876

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



    Illustration 13g01258463
    (L) Inside diameter of the bore of the idler
    (M) Width of idler hub
    (N) Bearing assembly inside diameter

    Note: Measure the clearance between the shaft and the bearing using the dimensions in Table 6 and Table 7.

  12. Measure the clearance between the shaft and the bearing. Refer to Table 5 for the correct dimensions.

    Table 5
    Clearance Between the Shaft and the Bearing 
    Sales Model  Clearance Minimum/Maximum 
    D10N
    D10R
    D10T
    D9N
    D9R
    D9T
    D8N
    D8R
    D8T
    D7E
    D7H
    D7R 
    0.44 mm to 0.56 mm (0.017 inch to 0.022 inch) 
    D6H
    D6R
    D6R2
    D6T 
    0.30 mm to 0.40 mm (0.012 inch to 0.016 inch) 
    D6N  0.52 mm to 0.30 mm (0.021 inch to 0.012 inch) 

    Note: Table 6 and Table 7 include the dimensions to determine the clearance between the shaft and the bearing. Refer to Illustration 13. The clearance may be checked with a 8H-8581 Gage-Feeler or using the dimensions in Table 6 and Table 7.

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

    Table 6
    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) 
    D10N
    D10R
    D10T 
    7T-0961  9W-6284  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) 
    D9N
    D9R
    D9T 
    7T-2770  9W-4468  133.32 ± 0.04 mm (5.250 ± 0.002 inch)  290.00 ± 0.13 mm (11.417 ± 0.005 inch)  9W-9499  127.25 ± 0.03 mm (5.010 ± 0.001 inch) 
    D8N
    D8R
    D8T 
    6Y-0556  6Y-0555  133.32 ± 0.04 mm (5.250 ± 0.002 inch)  250.00 ± 0.13 mm (9.843 ± 0.005 inch)  154-3298  127.25 ± 0.03 mm (5.010 ± 0.001 inch) 
    6Y-0553 6Y-0552  133.32 ± 0.04 mm (5.250 ± 0.002 inch)  250.00 ± 0.13 mm (9.843 ± 0.005 inch)  154-3298  127.25 ± 0.03 mm (5.010 ± 0.001 inch) 
    D7E  192-0223  192-0222  133.32 ± 0.04 mm (5.249 ± 0.002 inch)  216.00 ± 0.13 mm (8.504 ± 0.005 inch)  6Y-1757  127.25 ± 0.03 mm (5.010 ± 0.001 inch) 
    D7H
    D7R 
    192-0215  192-0214  133.32 ± 0.04 mm (5.250 ± 0.002 inch)  216.00 ± 0.13 mm (8.504 ± 0.005 inch)  6Y-1757  127.25 ± 0.03 mm (5.010 ± 0.001 inch) 
    192-0223 192-0222  133.32 ± 0.04 mm (5.250 ± 0.002 inch)  216.00 ± 0.13 mm (8.504 ± 0.005 inch)  6Y-1757  127.25 ± 0.03 mm (5.010 ± 0.001 inch) 
    D6H
    D6R
    D6R2
    D6T 
    202-4303  202-4302  114.28 ± 0.043 mm (4.500 ± 0.002 inch)  199.00 ± 0.13 mm (7.835 ± 0.005 inch)  9P-2245  108.06 ± 0.02 mm (4.254 ± 0.001 inch) 
    202-4295 202-4294  114.28 ± 0.043 mm (4.500 ± 0.002 inch)  199.00 ± 0.13 mm (7.835 ± 0.005 inch)  9P-2245  108.06 ± 0.02 mm (4.254 ± 0.001 inch) 
    D6N  323-1169  318-2951  102.0 ± 0.04 mm (4.02± 0.002 inch)  189.0 ± 0.13 mm (7.44 ± 0.005 inch)  9P-1360  95.96 ± 0.04 mm (3.778 ± 0.002 inch) 

    Table 7
    Specifications for the Shaft 
    Sales Model  Idler Assembly  Shaft  Outer Diameter of the Shaft  Length of the Bearing Surface 
    D10N
    D10R
    D10T 
    7T-0961  154-3308  136.28 ± 0.03 mm (5.365 ± 0.001 inch)  301.00 ± 0.10 mm (11.850 ± 0.004 inch) 
    D9N
    D9R
    D9T 
    7T-2770  154-3309  126.75 ± 0.03 mm (4.500 ± 0.001 inch)  265.00 ± 0.10 mm (10.433 ± 0.004 inch) 
    D8N
    D8R
    D8T 
    6Y-0556  154-3307  126.75 ± 0.03 mm (4.500 ± 0.001 inch)  225.00 ± 0.10 mm (8.858 ± 0.004 inch) 
    6Y-0553 154-3307  126.75 ± 0.03 mm (4.500 ± 0.001 inch)  225.00 ± 0.10 mm (8.858 ± 0.004 inch) 
    D7E  192-0223  351-8927  126.75 ± 0.03 mm (4.500 ± 0.001 inch)  191.00 ± 0.10 mm (7.520 ± 0.004 inch) 
    D7H
    D7R 
    192-0215  131-3935  126.75 ± 0.03 mm (4.500 ± 0.001 inch)  191.00 ± 0.10 mm (7.520 ± 0.004 inch) 
    192-0223 131-3935  126.75 ± 0.03 mm (4.500 ± 0.001 inch)  191.00 ± 0.10 mm (7.520 ± 0.004 inch) 
    D6H
    D6R
    D6R2
    D6T 
    202-4303  149-2494  107.71 ± 0.03 mm (4.241 ± 0.001 inch)  160.00 ± 0.05 mm (6.300 ± 0.002 inch) 
    202-4295 149-2494  107.71 ± 0.03 mm (4.241 ± 0.001 inch)  160.00 ± 0.05 mm (6.300 ± 0.002 inch) 
    D6N  323-1169  161-7350  95.43 ± 0.03 mm (3.757 ± 0.001 inch)  150.00 ± 0.10 mm (5.905 ± 0.004inch) 


    Illustration 14g01258576

  13. Remove the shaft from the idler. If necessary, attach a hoist to help remove the shaft. Take precaution not to damage the shaft surface during removal.


    NOTICE

    Correct assembly and installation procedures should be followed when using conventional Duo-Cone seals. Many failures are the result of mistakes made during assembly and installation of the seals.


  14. Wash all components to remove debris from the components.


    Illustration 15g01579194

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

Assembly of Idlers with Conventional Duo-Cone Seals



    Illustration 16g01258582


    Illustration 17g01258583

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

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



    Illustration 18g01258589

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

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


    NOTICE

    Misalignments, twists and bulges of the toric ring will cause Duo-Cone seal failures. If any of these occur, perform the assembly process over from the beginning.


  3. If the Duo-Cone seals are reused, replace the toric rings. Never reuse 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 8 for the correct seal installer.

    Table 8
    Duo-Cone Seal Installers 
    Sales Model  Part Number 
    D10N
    D10R
    D10T 
    129-1340 
    D9N
    D9R
    D9T
    D8N
    D8R
    D8T 
    227-4755 
    D7E
    D7H
    D7R
    D6H
    D6R
    D6R2
    D6T 
    136-6813 
    224-9467
    D6N  179-7208 

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


    Illustration 19g01258634

  6. Use a firm, even pressure to install the Duo-Cone seals into the end collars.


    Illustration 20g02140680

  7. Use a firm, even pressure on the installation tool to install the Duo-Cone seals in the retainer.


    Illustration 21g01584856


    Illustration 22g01258642

  8. Use 8T-0447 Dial Caliper to check the height of the assembled Duo-Cone seals in the retainers and the end collars. Take measurements at four 90° 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 the lubricant being sealed in the idler.


    Illustration 23g01258656

  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.

    Note: Follow the correct procedure for pinned or not pinned thrust washers.



    Illustration 24g01258663
    The thrust ring is pinned onto the retainer.

    Note: Install the thrust washer onto the retainer assembly. Refer to Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers" for the procedures to pin thrust washers onto the retainer assembly.



    Illustration 25g01258662
    The thrust ring is not pinned on the retainer.

  11. Install the thrust washers on both ends of the idler shaft if the thrust washers are not pinned on the retainer assembly.

  12. Install the retainer assemblies over the shaft and carefully move the retainer into the final position.


    Illustration 26g01258682

  13. Install two bolts at 180° and firmly tighten the bolts.

  14. Lubricate the circumference of the stopper with a lightweight oil. Use the correct installer tool to install the stopper in the end of the shaft. Refer to Table 9 for the correct installer tool. The stopper must be installed 7 ± 15 mm (0.28 ± 0.59 inch) below the surface of the shaft.

    Table 9
    Installer Tool Group 
    Sales Model  Part Number 
    D10N
    D10R
    D10T
    D9N
    D9R
    D9T
    D8N
    D8R
    D8T 
    228-0600 
    D7E
    D7H
    D7R
    D6H
    D6R
    D6R2
    D6T
    D6N 
    228-0597 


    Illustration 27g01258675


    Illustration 28g01258676

  15. 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 .


    NOTICE

    Never permit oil to get on the toric rings or ramps before both seal rings are put together in their final assembled position.




    Illustration 29g01258684

  16. Use Tooling 1U-9977 Brush to apply a thin film of lubricant being sealed in the idler on the entire Duo-Cone seal face.

    Note: 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.



    Illustration 30g01258689

  17. Position the end collars on the shaft.


    Illustration 31g01258691

  18. Use a hydraulic press to press the end collar into the final position. Refer to Table 10 for the correct tooling for the end collar.

    Note: Use approximately 22240 N (5000lb) to install the end collar.

    Table 10
    Tooling for the End Collar 
    Sales Model  Part Number 
    D10N
    D10R
    D10T 
    170-5406 
    D9N
    D9R
    D9T 
    170-5409 
    D8N
    D8R
    D8T 
    170-5408 
    D7E
    D7H
    D7R 
    170-5411 
    D6H
    D6R
    D6R2
    D6T 
    170-5412 
    D6N  201-1581 

  19. Repeat Step 18 to install the other end collar.


    Illustration 32g01258717

  20. Check end play by using 8T-5096 Dial Indicator Test Group on the assembled idler. Install the magnetic base onto the face of the retainer assembly. Adjust the arms and the indicator as shown. Refer to Table 11 for the correct dimensions.

    Table 11
    End Play Dimensions 
    Sales Model  End Play Minimum to Maximum 
    D10N
    D10R
    D10T
    D9N
    D9R
    D9T
    D8N
    D8R
    D8T 
    0.33 mm (0.013 inch) to 1.19 mm (0.047 inch) 
    D7E
    D7H
    D7R 
    0.38 mm (0.015 inch) to 1.24 mm (0.048 inch) 
    D6H
    D6R
    D6R2
    D6T 
    0.25 mm (0.010 inch) to 1.25 mm (0.050 inch) 
    D6N  0.38 mm (0.015 inch) to 1.24 mm (0.048 inch) 


    Illustration 33g02182855

  21. 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.


    Illustration 34g02182845

  22. 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.

    Note: If the end play is incorrect, the idler must be disassembled.



    Illustration 35g01258721

  23. Use the correct spin socket to spin the shaft. Refer to Table 12 for the correct spin socket. The shaft should be spun 20 revolutions in each direction at a maximum of 100 rpm.

    Table 12
    Spin Socket Tooling 
    Sales Model  Part Number 
    D10N
    D10R
    D10T 
    FT1909 
    D9N
    D9R
    D9T
    D8N
    D8R
    D8T 
    FT1910 
    D7E
    D7H
    D7R
    D6H
    D6R
    D6R2
    D6T
    D6N 
    FT1911 

  24. Remove the two bolts that were installed earlier to hold the retainer assembly in place.

  25. Install the plates on both sides of the idler.


    Illustration 36g01259143

  26. Use Loctite® C5-A® lubricant on bolt threads. Install the bolts into the plates and retainers and torque the bolts to the correct torque value. Refer to Table 13 for the correct torque.

    Table 13
    Torque Specifications 
    Sales Model  Dynamic Assembly Torque 
    D10N
    D10R
    D10T 
    135 ± 20 N·m (100.0 ± 15.0 lb ft) 
    D9N
    D9R
    D9T
    D8N
    D8R
    D8T
    D7E
    D7H
    D7R 
    85 ± 15 N·m (63.0 ± 11.0 lb ft) 
    D6H
    D6R
    D6R2
    D6T
    D6N 
    55 ± 10 N·m (41.0 ± 7.0 lb ft) 

Test and Fill



    Illustration 37g01585599


    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.


  1. Use 170-5664 Test and Fill Cart Gp in order to evaluate and fill the idler.


    Illustration 38g01585600

  2. 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.

  3. Add the correct quantity of oil to the idler. Refer to Table 14 or Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for the correct oil volume.

    Table 14
    Sales Model  Idler Assembly  Oil Volume  Oil Weight  CAT Oil Part Number 
    D10N
    D10R
    D10T 
    7T-0961  850 ± 20 mL (28.7 ± 0.68 oz)  Cat FDOA Syn Oil  18L
    206-5211
    -
    208 L
    206-5212
    -
    5 gal
    208-2390
    -
    55 gal
    198-7450 
    D9N
    D9R
    D9T 
    7T-2770  850 ± 20 mL (28.7 ± 0.68 oz)  SAE 5W 40  347-8470 
    775 ± 40 mL (26.2 ± 1.35 oz) SAE 15W 40 DEO 3E-9712 
    775 ± 40 mL (26.2 ± 1.35 oz) SAE 15W 40 DEO 347-8470 
    SAE 5W 40
    D8N
    D8R
    D8T 
    6Y-0553  600 ± 15 mL (20.3 ± 0.5 oz)  SAE 5W 40  347-8470 
    600 ± 30 mL (20.3 ± 1.01 oz) SAE 15 W 40 DEO 3E-9712 
    SAE 5W 40 347-8470
    6Y-0556 600 ± 15 mL (20.3 ± 0.5 oz)
    600 ± 30 mL (20.3 ± 1.01 oz)
    SAE 15 W 40 DEO 3E-9712 
    D7E  192-0223  650 ± 15 mL (22.0 ± 0.50 oz)  SAE 15 W 40 DEO  3E-9712 
    D7H  192-0215  650 ± 15 mL (22.0 ± 0.50 oz)  SAE 15 W 40 DEO  3E-9712 
    192-0223 660 ± 35 mL (22.4 ± 1.19 oz) 
    192-0223 650 ± 15 mL (22.0 ± 0.50 oz)  SAE 5W 40  347-8474 
    D7R  192-0215  650 ± 35 mL (22.0 ± 1.19 oz)  SAE 15 W 40 DEO  3E-9712 
    192-0223 650 ± 15 mL (22.0 ± 0.50 oz) 
    D6H  202-4295  540 ± 15 mL (18.4 ± 0.50 oz)  SAE 15 W 40 DEO  3E-9712 
    540 ± 25 mL (18.4 ± 0.85 oz)
    202-4303 540 ± 15 mL (18.4 ± 0.50 oz) 
    D6N  323-1169  440 ± 10 mL (15 ± 0.3 oz)  SAE 15 W 40 DEO  3E-9712 
    D6R
    D6R2 
    202-4295  540 ± 15 mL (18.4 ± 0.50 oz)  SAE 15 W 40 DEO  3E-9712 
    540 ± 25 mL (18.4 ± 0.85 oz)
    202-4303 540 ± 15 mL (18.4 ± 0.50 oz) 
    D6T  202-4295  540 ± 15 mL (18.4 ± 0.50 oz)  SAE 15 W 40 DEO  3E-9712 
    202-4303 540 ± 15 mL (18.4 ± 0.50 oz) 
    202-4295 540 ± 25 mL (18.4 ± 0.85 oz) 


    Illustration 39g01585603

  4. Use 5P-7419 Installer Plug Tool 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.



    Illustration 40g01259148

  5. Tap the end of the idler shaft 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.

Disassembly and Assembly Procedures for Landfill Idlers with Inverted Duo-Cone Seals



Illustration 41g01259097
(1) Retainer
(2) Seal guard
(3) Duo-Cone seal
(4) Snap ring
(5) Retainer bolt

The seal guard is used to provide improved protection for the Duo-Cone seal. Refer to Service Magazine, SEPD0161 for more information. The procedures for Disassembly and Assembly for landfill idlers with the inverted Duo-Cone seal are similar to idlers with the inverted Duo-Cone seals. Except for the installation and removal of an extra seal guard (2) and snap ring (4).

The seal guard should be replaced if the guard is bent or the center hole is enlarged or worn.

Disassembly

  1. Use a suitable tool to remove snap ring (4).

  2. Remove guard (2) from the idler assembly.

  3. Clean out all the old grease under the seal guard.

Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals" for further disassembly procedures.

Assembly

Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals" to assemble the idler.

  1. Remove the plug from the retainer assembly on both sides of the idler.

  2. Install Tooling (H) into one of the holes. Leave the other hole open.

  3. Fill the cavity between the Duo-Cone seal and the guard through the grease fitting with 2P-9066 Multipurpose Grease.

    Note: Fill the cavity slowly to prevent displacement of the Duo-Cone seal.

    Note: Grease will flow from the open hole when the cavity is full.

  4. Remove the fitting and install the plugs into both holes.

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