Hydraulic Excavator Idler Disassembly and Assembly Procedures {0729, 4159} Caterpillar


Hydraulic Excavator Idler Disassembly and Assembly Procedures {0729, 4159}

Usage:

TK711 101
Caterpillar Products
Machines with Greased Lubricated Track (GLT)
Machines with Positive Pin Retention 2 (PPR2) Track
Machines with Sealed Positive Pin Retention (PPR) Track

Introduction

Table 1
Revision  Summary of Changes in SEBF8495 
18  Added serial number prefixes for New Product Introduction. 
17  Added serial number prefixes for New Product Introduction.
Added 311F, 312D2, 318D2, 323D2, 325F, 336F, 352F, 538B, and 6015B to tables. 
16  RPE SEBF8495, Hydraulic Excavator Idler Disassembly and Assembly ProceduresAdded 312F, 313F, 316F318F, 320F, 323D2, and 336D2 to document. 
15  Added serial number prefixes for New Product Introduction.
Added 374F and 390Fto document. 
14  Added serial number prefixes for New Product Introduction.
Added 307E2, 308E2, and 312D2. 

© 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).

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

Summary

The following information provides Disassembly and Assembly procedures. The information in the bulletin should serve as an aid in determining whether a Hydraulic Excavator idler can be reconditioned. Correct any conditions which may have caused the original failure during the rebuild.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599

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

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8596, "Guideline for Roller and Idler Component Reuse"

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

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

Reference: Special Instructions, SEHS8484, "Tool and Specification Chart for Conventional Duo-Cone Seal"

Reference: Special Instructions, SEHS8364, "Assembly and Installation of Conventional Duo-Cone Seals"

Reference: Catalog, NENG2500, "Dealer Service Tools Catalog"

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 ones 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.


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

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.

Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.

U.S. Department of Labor
Washington, D.C. 20210

Canceled Part Numbers and Replaced Part Numbers

This document does not include all Canceled part number and replaced part number information. 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
Part Number  Description 
FT-1238  Vacuum Tank Assembly 
8T-0447  Dial Caliper As 
5P-7419  Installer Tool 
369-9450  Grease-Petro Gel 
3E-9712  15W40 DEO 55 Gal Drum 
9S-3263  Thread Lock Compound 

Disassembly



    Illustration 2g02019155

  1. Clean the exterior of the idler. Place the idler on a table for service.


    Illustration 3g03880461

  2. Remove the plug to drain the oil from the idler.

  3. Use FT-1238 Vacuum Tank Assembly to drain the oil.


    Illustration 4g03880467

  4. Use a punch and a hammer to remove the two retaining pins.


    Illustration 5g02019253

  5. Use a puller to remove the two bearing blocks from the idler shaft. The bearing block weighs approximately 18 kg (40.0 lb).


    Illustration 6g02019274

  6. Remove the O-ring seal from the shaft.


    Illustration 7g02019993

  7. Remove the Duo-Cone seals from the bearing blocks and the idler assembly.

  8. 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.

  9. Measure the clearance between the shaft and bearing at the top center position of the idler. Refer to Table 3 for the correct dimensions.

    Note: Table 4 and Table 5 include the dimensions to determine the clearance between the shaft and the bearing. A feeler gauge may be used as a quick check for the clearance.

    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 3
    Clearance Between the Shaft and the Bearing 
    Sales Model  Idler Group  Maximum Clearance  Minimum Clearance 
    307
    307B 
    115-6336  0.27 mm (0.011 inch)  0.10 mm (0.004 inch) 
    307E2
    308E2 
    422-0868
    433-3881 
    0.27 mm (0.011 inch)  0.10 mm (0.004 inch) 
    307B
    307C
    307D
    308C
    308D 
    277-8667  0.27 mm (0.011 inch)  0.10 mm (0.004 inch) 
    311
    311B
    311C
    311D
    311F
    312
    312B
    312C
    312D
    312D2
    312E
    312F
    313B
    313C
    313D
    313D2
    313F
    314C
    314E 
    4I-7337  0.29 mm (0.011 inch)  0.11 mm (0.004 inch) 
    313D2
    315
    315B
    315C
    315D
    316F
    317
    317B
    318B
    318C
    318D
    318D2
    318E
    318F
    319C
    319D
    320
    320B
    320C
    320D
    320D2
    320E
    320F
    321C
    321D
    323D
    323D2
    323F
    325F
    MD5075
    MD5075C
    MD5150
    MD5150C 
    248-7143  0.35 mm (0.014 inch)  0.12 mm (0.005 inch) 
    538B  386-4139  0.35 mm (0.014 inch)  0.12 mm (0.005 inch) 
    320
    325 
    102-8155  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    320B
    320C
    322C
    323D
    323D2
    324D
    325B
    325C
    325D
    329D 
    115-3696  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    322B
    322C
    324D
    326D 
    115-6337  0.35 mm (0.014 inch)  0.12 mm (0.005 inch) 
    322C  194-1130  0.35 mm (0.014 inch)  0.12 mm (0.005 inch) 
    325D  239-3690  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    328D
    330
    330B
    330C
    330D
    336D
    336D2
    336E
    336F
    340D
    340D2
    MD6240
    MD6290 
    136-2422  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    330  102-8152  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    330D  239-3691  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    312D2
    330C
    330D
    345B
    345C
    345D
    349E
    349D
    349F
    568
    MD6420
    MD6420B
    MD6420C 
    248-7151  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    345B
    345C
    345D
    3459D 
    297-9264  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    350  135-8903  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    352F  357-7995     
    365B
    365C 
    136-2429
    248-7256 
    0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    374D
    374F
    365C
    365CL
    365B
    365BL
    MD6640
    MD6540
    MD6540C 
    340-8250  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    375
    5080 
    135-8904  0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    385B
    385C
    5090 
    194-1157
    248-7257 
    0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    390D
    390F 
    248-7257
    340-8242 
    0.48 mm (0.019 inch)  0.25 mm (0.010 inch) 
    5110B  121-7351  0.42 mm (0.017 inch)  0.24 mm (0.009 inch) 
    6015B  430-4193  0.42 mm (0.017 inch)  0.24 mm (0.009 inch) 

    Table 4
    Dimensions for Rebuilding the Idler 
    Sales Model  Idler Assembly  Inside Diameter of the Idler  Width of the Hub  Part Number for the Bearing  Inside Diameter of the Bearing Assembly 
    307E2
    308E2 
    422-0870  54.015 ± 0.015 mm (2.12657 ± 0.00059 inch)  89 ± 0.1 mm (3.504 ± 0.004 inch)  294-5350  51 ± 0.07 mm (2.008 ± 0.003 inch) 
    294-5349 50.114 ± 0.068 mm (1.97299 ± 0.00268 inch)  92.75 ± 0.2 mm (3.65 ± 0.008inch) 
    307
    307B 
    115-6335  44.0125 ± 0.0125 mm (1.73277 ± 0.00050 inch)  89.0 ± 0.1 mm (3.50 ± 0.004 inch)  5I-6274  40.112 ± 0.066 mm (1.5792 ± 0.0026 inch) 
    307B
    307C
    307D
    308C
    308D 
    277-8669  44.0125 ± 0.0125 mm (1.73277 ± 0.00050 inch)  89.0 ± 0.1 mm (3.50 ± 0.004 inch)  5I-6274  40.112 ± 0.066 mm (1.5792 ± 0.0026 inch) 
    311
    311B
    311C
    311D
    311F
    312
    312B
    312C
    312D
    312D2
    312E
    312F
    313B
    313C
    313D
    313F
    314C
    314E
    314F
    315F 
    6I-6590  59.015 ± 0.015 mm (2.3234 ± 0.0006 inch)  110.0 ± 0.1 mm (4.33 ± 0.004 inch)  099-0157  55.114 ± 0.068 mm (2.1698 ± 0.0027 inch) 
    313D2
    315
    315B
    315C
    315D
    316F
    317
    317B
    318B
    318C
    318D
    318E
    318F
    319C
    319D
    320
    320B
    320C
    320D
    320D2
    320E
    320F
    321C
    321D
    323D
    323F
    323D2
    325F
    MD5075
    MD5075C
    MD5150
    MD5150C 
    262-4781  72.015 ± 0.025 mm (2.8352 ± 0.0010 inch)  135.8 ± 0.1 mm (5.35 ± 0.004 inch)  8E-4359  65.15 ± 0.09 mm (2.565 ± 0.004 inch) 
    538B  384-5482  72.015 ± 0.025 mm (2.8352 ± 0.0010 inch)  135.8 ± 0.1 mm (5.35 ± 0.004 inch)  8E-4359  65.15 ± 0.09 mm (2.565 ± 0.004 inch) 
    320
    320B
    320C
    322C
    323D
    324D
    325
    325B
    325C
    325D
    329D 
    115-7471  82.155 ± 0.025 mm (3.2344 ± 0.0010 inch)  149.2 ± 0.1 mm (5.87 ± 0.004 inch)  6Y-2272  75.31 ± 0.09 mm (2.965 ± 0.004 inch) 
    322
    322B
    322C
    324D
    326D 
    115-4931  77.980 ± 0.025 mm (3.0701 ± 0.0010 inch)  140.0 ± 0.1 mm (5.51 ± 0.004 inch)  6I-9587  70.065 ± 0.09 mm (2.7585 ± 0.0035 inch) 
    325D  235-8531  82.155 ± 0.025 mm (3.2344 ± 0.0010 inch)  149.2 ± 0.1 mm (5.87 ± 0.004 inch)  6Y-2272  75.31 ± 0.09 mm (2.965 ± 0.004 inch) 
    328D
    330
    330B
    330C
    330D
    336D
    336D2
    336E
    340D
    340D2
    MD6240
    MD6290 
    136-3847  92.210 ± 0.025 mm (3.6303 ± 0.0010 inch)  175.2 ± 0.1 mm (6.90 ± 0.004 inch)  6Y-8023  85.365 ± 0.09 mm (3.3608 ± 0.0035 inch) 
    330D  235-8536  92.210 ± 0.025 mm (3.6303 ± 0.0010 inch)  175.2 ± 0.1 mm (6.90 ± 0.004 inch)  6Y-8023  85.365 ± 0.09 mm (3.3608 ± 0.0035 inch) 
    312D2
    330C
    330D
    345B
    345C
    345D
    349E
    349D
    568
    MD6420
    MD6420B
    MD6420C 
    264-9821  112.125 ± 0.025 mm (4.4144 ± 0.0010 inch)  175.2 ± 0.1 mm (6.90 ± 0.004 inch)  124-9979  105.28 ± 0.09 mm (4.145 ± 0.004 inch) 
    345B
    345C
    345D
    349D 
    337-6894  112.125 ± 0.025 mm (4.4144 ± 0.0010 inch)  175.2 ± 0.1 mm (6.90 ± 0.004 inch)  124-9979  105.28 ± 0.09 mm (4.145 ± 0.004 inch) 
    350  138-8389  112.125 ± 0.025 mm (4.4144 ± 0.0010 inch)  220.2 ± 0.1 mm (8.67 ± 0.004 inch)  8E-4343  105.28 ± 0.09 mm (4.145 ± 0.004 inch) 
    352F  383-1612  112.125 ± 0.025 mm (4.4144 ± 0.0010 inch)  175.2 ± 0.1 mm (6.90 ± 0.004 inch)  124-9979  105.28 ± 0.09 mm (4.145 ± 0.004 inch) 
    365B
    365C 
    141-2697  122.155 ± 0.025 mm (4.8092 ± 0.0010 inch)  253.2 ± 0.1 mm (9.97 ± 0.004 inch)  6Y-7599  115.31 ± 0.09 mm (4.540 ± 0.004 inch) 
    365B
    365C 
    278-7284  122.155 ± 0.025 mm (4.8092 ± 0.0010 inch)  253.2 ± 0.1 mm (9.97 ± 0.004 inch)  6Y-7599  115.31 ± 0.09 mm (4.540 ± 0.004 inch) 
    374D
    374F
    365C
    365CL
    365B
    365BL
    MD6640
    MD6540
    MD6540C 
    352-3735  122.155 ± 0.025 mm (4.8092 ± 0.0010 inch)  253.2 ± 0.1 mm (9.97 ± 0.004 inch)  6Y-7599  115.31 ± 0.09 mm (4.540 ± 0.004 inch) 
    375
    5080 
    138-8388  122.155 ± 0.025 mm (4.8092 ± 0.0010 inch)  253.2 ± 0.1 mm (9.97 ± 0.004 inch)  6Y-7599  115.31 ± 0.09 mm (4.540 ± 0.004 inch) 
    385B
    385C
    5090 
    203-4862  122.155 ± 0.025 mm (4.8092 ± 0.0010 inch)  253.2 ± 0.1 mm (9.97 ± 0.004 inch)  6Y-7599  115.31 ± 0.09 mm (4.540 ± 0.004 inch) 
    385B
    385C
    5090 
    278-7286  122.155 ± 0.025 mm (4.8092 ± 0.0010 inch)  253.2 ± 0.1 mm (9.97 ± 0.004 inch)  6Y-7599  115.31 ± 0.09 mm (4.540 ± 0.004 inch) 
    390D
    390F 
    278-7286
    352-3740 
    122.155 ± 0.025 mm (4.8092 ± 0.0010 inch)  253.2 ± 0.1 mm (9.97 ± 0.004 inch)  6Y-7599  115.31 ± 0.09 mm (4.540 ± 0.004 inch) 
    5110B  121-7351  166.000 ± 0.025 mm (6.5354 ± 0.0010 inch)  266.0 ± 0.1 mm (10.47 ± 0.004 inch)  121-7371  150.180 ± 0.065 mm (5.9126 ± 0.0026 inch) 
    6015B  435-4448  166.000 ± 0.025 mm (6.5354 ± 0.0010 inch)  266.0 ± 0.1 mm (10.47 ± 0.004 inch)  121-7371  150.180 ± 0.065 mm (5.9126 ± 0.0026 inch) 

    Table 5
    Specifications for the Shaft 
    Sales Model  Idler Assembly  Shaft  Outside Diameter of the Shaft  Length of the Bearing Surface 
    307E2
    308E2 
    422-0870  422-0871  49.93 ± 0.02 mm (1.96574 ± 0.00079 inch)  69 ± 0.5 mm (2.72 ± 0.02 inch) 
    294-5349 294-5348 
    307
    307B 
    115-6335  102-8082  39.93 ± 0.02 mm (1.572 ± 0.001 inch)  92.75 ± 0.20 mm (3.652 ± 0.008 inch) 
    307B
    307C
    307D
    308C
    308D 
    277-8668  185-9185  39.93 ± 0.02 mm (1.572 ± 0.001 inch)  92.75 ± 0.20 mm (3.652 ± 0.008 inch) 
    311
    311B
    311C
    311D
    311F
    312
    312B
    312C
    312D
    312D2
    312E
    312F
    313B
    313C
    313D
    313F
    314C
    314E 
    6I-6590  6I-6477  54.917 ± 0.023 mm (2.1621 ± 0.0009 inch)  119.04 ± 0.20 mm (4.687 ± 0.008 inch) 
    313D2
    315
    315B
    315C
    315D
    316F
    317
    317B
    318B
    318C
    318D
    318D2
    318E
    318F
    319
    319D
    320
    320B
    320C
    320D
    320D2
    320E
    320F
    321C
    321D
    323D
    323D2
    323F
    MD5075
    MD5075C
    MD5150
    MD5150C 
    262-4781  246-5425  64.915 ± 0.025 mm (2.5557 ± 0.0010 inch)  144.84 ± 0.15 mm (5.702 ± 0.006 inch) 
    538B  384-5482  246-5425  64.915 ± 0.025 mm (2.5557 ± 0.0010 inch)  144.84 ± 0.15 mm (5.702 ± 0.006 inch) 
    320
    320B
    320C
    322C
    323D
    324D
    325
    325B
    325C
    325D
    329D 
    115-7471  112-9951  74.945 ± 0.025 mm (2.9506 ± 0.0010 inch)  158.24 ± 0.20 mm (6.230 ± 0.008 inch) 
    322
    322B
    322C
    324D
    326D 
    115-4931  6I-9597  69.83 ± 0.025 mm (2.7492 ± 0.0010 inch)  149.00 ± 0.20 mm (5.866 ± 0.008 inch) 
    325D  235-8531  112-9951  74.945 ± 0.025 mm (2.9506 ± 0.0010 inch)  158.24 ± 0.20 mm (6.230 ± 0.008 inch) 
    328D
    330
    330B
    330C
    330D
    336D
    336D2
    336E
    340D
    340D2
    MD6240
    MD6290 
    136-3847  6Y-8028  85.000 ± 0.025 mm (3.3465 ± 0.0010 inch)  184.24 ± 0.20 mm (7.254 ± 0.008 inch) 
    330D  235-8536  6Y-8028  85.000 ± 0.025 mm (3.3465 ± 0.0010 inch)  184.24 ± 0.20 mm (7.254 ± 0.008 inch) 
    312D2
    330C
    330D
    345B
    345C
    345D
    349E
    349D
    568
    MD6420
    MD6420B
    MD6420C 
    264-9821  124-9978  104.915 ± 0.025 mm (4.1305 ± 0.0010 inch)  184.24 ± 0.20 mm (7.254 ± 0.008 inch) 
    345B
    345C
    345D
    349D 
    337-6894  293-8216  104.915 ± 0.025 mm (4.1305 ± 0.0010 inch)  184.24 ± 0.20 mm (7.254 ± 0.008 inch) 
    350  138-8389  8E-4335  104.915 ± 0.025 mm (4.1305 ± 0.0010 inch)  229.24 ± 0.20 mm (9.025 ± 0.008 inch) 
    352F  357-7559  293-8216  104.915 ± 0.025 mm (4.1305 ± 0.0010 inch)  184.24 ± 0.20 mm (7.254 ± 0.008 inch) 
    365B
    365C 
    141-2697  6Y-7602  114.945 ± 0.025 mm (4.5254 ± 0.0010 inch)  262.24 ± 0.20 mm (10.324 ± 0.008 inch) 
    365B
    365C 
    278-7284  293-8217  114.945 ± 0.025 mm (4.5254 ± 0.0010 inch)  262.24 ± 0.20 mm (10.324 ± 0.008 inch) 
    374D
    374F
    365C
    365CL
    365B
    365BL
    MD6640
    MD6540
    MD6540C 
    352-3735  293-8218  114.945 ± 0.025 mm (4.5254 ± 0.0010 inch)  262.24 ± 0.20 mm (10.324 ± 0.008 inch) 
    375
    5080 
    138-8388  6Y-7602  114.945 ± 0.025 mm (4.5254 ± 0.0010 inch)  262.24 ± 0.20 mm (10.324 ± 0.008 inch) 
    385B
    385C
    5090 
    203-4862  202-4902  114.945 ± 0.025 mm (4.5254 ± 0.0010 inch)  262.24 ± 0.20 mm (10.324 ± 0.008 inch) 
    385B
    385C
    390D
    390F
    5090 
    278-7286
    352-3740 
    293-8218  114.945 ± 0.025 mm (4.5254 ± 0.0010 inch)  262.24 ± 0.20 mm (10.324 ± 0.008 inch) 
    5110B  121-7351  123-1227  149.850 ± 0.025 mm (5.8996 ± 0.0010 inch)  286.0 ± 0.2 mm (11.26 ± 0.01 inch) 
    6015B  435-4448  123-1227  149.850 ± 0.025 mm (5.8996 ± 0.0010 inch)  286.0 ± 0.2 mm (11.26 ± 0.01 inch) 


    Illustration 8g02020097

  10. Remove the shaft from the idler. If necessary, attach a hoist to help remove the shaft.

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

Assembly



    Illustration 9g02020233

  1. Clean the Duo-Cone seals with isopropyl alcohol. Always use new toric rings for assembly.

    Note: Make sure that the toric ring is not twisted on the seal ring.



    Illustration 10g02020253

  2. Clean the idler with isopropyl alcohol.


    Illustration 11g02020334

  3. Clean the contact surface area for the toric rings in the bearing blocks with isopropyl alcohol.


    Illustration 12g02020353

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


    Illustration 13g02020433

  5. Use a firm, even pressure on the installation tool to install the Duo-Cone seal in the bearing block. Refer to Table 6 for the correct installation tool.


    Illustration 14g02020498

  6. Use a firm, even pressure on the installation tool to install the Duo-Cone seal into the idler assembly. Refer to Table 6 for the correct installation tool.

    Table 6
    Duo-Cone Seal Installation 
    Sales Model  Seal Installer  Seal Height 
    307
    307B
    307C
    307D
    307E2
    308C
    308D
    308E
    308E2 
    123-3801  7.7 ± 0.6 mm (0.30 ± 0.02 inch) 
    311
    311B
    311C
    311D
    311F
    312
    312B
    312C
    312D
    312D2
    312E
    312F
    313B
    313C
    313D
    313F
    314C
    314E 
    1U-8850  8.8 ± 0.6 mm (0.35 ± 0.02 inch) 
    313D2(1)
    315
    315B
    315C
    315D
    316F
    317
    317B
    318B
    318C
    318D
    318D2
    318E
    318F
    319C
    319D
    320(1)
    320B(1)
    320C(1)
    320D
    320D2(1)
    320E(1)
    320F(1)
    321C
    321D
    323D(1)
    323D2(1)
    323F
    325F
    MD5075
    MD5075C
    MD5150
    MD5150C
    538B 
    1U-8842  8.8 ± 0.6 mm (0.35 ± 0.02 inch) 
    320(2)
    320B(2)
    320C(2)
    323D(2)
    322
    322B
    322C
    324D
    325
    325B
    325C
    325D
    326D
    329D 
    9U-7537  8.8 ± 0.6 mm (0.35 ± 0.02 inch) 
    328D
    330
    330B
    330C(3)
    330D(3)
    336D
    336E
    336D2
    340D
    340D2
    MD6240
    MD6290 
    1U-8849  8.8 ± 0.6 mm (0.35 ± 0.02 inch) 
    330C(4)
    330D(4)
    345B
    345C
    345D
    349E
    349D
    350
    352F
    568
    MD6420
    MD6420B
    MD6420C 
    4C-6206  8.8 ± 0.6 mm (0.35 ± 0.02 inch) 
    365B
    365BL
    365C
    365CL
    374D
    374F
    375
    385B
    385C
    390D
    390F
    5080
    5090
    MD6640
    MD6540
    MD6540C 
    9U-7538  8.8 ± 0.6 mm (0.35 ± 0.02 inch) 
    5110B
    6015B 
    1U-6436  11.5 ± 1.0 mm (0.45 ± 0.04 inch) 
    (1) 9W-2201 Duo-Cone Seal Gp
    (2) 109-0885 Duo-Cone Seal Gp
    (3) 109-0881 Duo-Cone Seal Gp
    (4) 109-0868 Duo-Cone Seal Gp


    Illustration 15g02020523

  7. Use 8T-0447 Dial Caliper As to check the height of the assembled Duo-Cone seal in the bearing blocks and idler assembly. The seal height should be checked at four 90 degree locations. Refer to Table 6 for the correct seal height.

    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 be reinstalled.



    Illustration 16g02020533

  8. Make sure that the seal faces are free of all debris. Apply a thin film of 3E-9712 Oil to the entire seal ring face in the idler assembly.


    NOTICE

    Do not get oil on the rubber toric rings. Oil on the rubber toric rings could lead to a failure.




    Illustration 17g02020537

  9. Lightly lubricate the idler bearings with 3E-9712 Oil.


    Illustration 18g02020577

  10. Make sure that the seal faces are free of all debris. Apply a thin film of 3E-9712 Oil to the entire seal ring face in the bearing blocks.


    Illustration 19g02020613

  11. Carefully install the shaft into the idler assembly.

    Note: The shaft may scrape bronze particles from the bearing. The bronze particles will cause failure in the idler.



    Illustration 20g02020615

  12. Apply 369-9450 Grease-Petro Gel to the new O-rings to install the new O-rings into the grooves on each end of the shaft.

    Note: Always use new O-rings on the ends of the shaft.



    Illustration 21g02020633

  13. Place one bearing block on the shaft. Make sure that the spring pin hole in the shaft is aligned with the spring pin hole in the bearing block. Make sure that the marking "R" and the milled surface of the shaft are facing toward the rear of the bearing block when the idler is positioned on the machine.

    Note: Always use a new spring pin after disassembly.



    Illustration 22g02020636

  14. Install the new spring pin into the bearing block and the shaft.

  15. Repeat Step 13 and Step 14 to install the other bearing block onto the shaft.

  16. Spin the bearing blocks and the shaft. The shaft should be spun 20 revolutions in each direction.

  17. Check the end play. Refer to Table 7 for the correct end play.

    Table 7
    Sales Model  Idler Group  End Play 
    307
    307B 
    115-6336  0.10 mm to 1.20 mm (0.004 inch to 0.050 inch) 
    307B
    307C
    307D
    308C
    308D 
    277-8667  0.1 mm to 1.2 mm (0.004 inch to 0.047 inch) 
    307E2
    308E2 
    422-0868  0.10 mm to 1.20 mm (0.004 inch to 0.050 inch) 
    433-3881
    311
    311B
    311C
    311D
    311F
    312
    312B
    312C
    312D
    312D2
    312E
    312F
    313B
    313C
    313D
    313F
    314C
    314E 
    4I-7337  0.06 mm to 1.06 mm (0.002 inch to 0.042 inch) 
    313D2
    315
    315B
    315C
    315D
    316F
    317
    317B
    318B
    318C
    318D
    318D2
    318E
    318F
    319C
    319D
    320
    320B
    320C
    320D
    320D2
    320E
    320F
    321C
    321D
    323D
    323D2
    323F
    325F
    MD5075
    MD5075C
    MD5150
    MD5150C 
    248-7143  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    538B  386-4139  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    320
    325 
    102-8155  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    320B
    320C
    322C
    323D
    324D
    325B
    325C
    325D
    329D 
    115-3696  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    322B
    322C
    324D
    326D 
    115-6337  0.25 mm to 1.15 mm (0.010 inch to 0.045 inch) 
    322C  194-1130  0.25 mm to 1.15 mm (0.010 inch to 0.045 inch) 
    325D  239-3690  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    328D
    330
    330B
    330C
    330D
    336D
    336D2
    336E
    340D
    340D2
    MD6240
    MD6290 
    136-2422  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    330  102-8152  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    330D  239-3691  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    312D2
    330C
    330D
    345B
    345C
    345D
    349E
    349D
    568
    MD6420
    MD6420B
    MD6420C 
    248-7151  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    345B
    345C
    345D
    349D 
    297-9264  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    350  135-8903  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    352F  357-7559  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    365B
    365C 
    136-2429
    248-7256 
    0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    374D
    374F
    365C
    365CL
    365B
    365BL
    MD6640
    MD6540
    MD6540C 
    340-8250  0.41 mm to 1.82 mm (0.016 inch to 0.072 inch) 
    375
    5080 
    135-8904  0.26 mm to 1.26 mm (0.010 inch to 0.050 inch) 
    390D
    390F 
    248-7257
    340-8250 
    0.41 mm to 1.82 mm (0.016 inch to 0.072 inch) 
    385B
    385C
    5090 
    194-1157
    248-7257 
    0.41 mm to 1.82 mm (0.016 inch to 0.072 inch) 
    6015B  430-4139  0.2 mm to 1.2 mm (0.008 inch to 0.047 inch) 

    Note: If the end play does not meet the specifications, the idler must be disassembled.



    Illustration 23g02020653

  18. The idlers use a threaded plug in the hub to seal the oil cavity. A compression fitting must be used to perform a pressure test on the assembled idler.


    Illustration 24g02020655


    NOTICE

    Do not allow a surge of air to enter the


  19. Use 170-5664 Test and Fill Cart Gp to evaluate the idler and fill the idler with oil.


    Illustration 25g02048293

  20. If 170-5664 Test and Fill Cart Gp is not available, use FT-2724 Pressure Gauge Tool Gp 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 of 3.4 kPa (0.50 psi) or less is acceptable.

    5. Add the correct quantity of 3E-9712 Oil to the idler. Refer to Table 8 or Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for the oil volumes.

      Table 8
      Sales Model  Idler Group  Oil Volumes 
      307
      307B 
      115-6336  60 ± 5 mL (2.0 ± 0.2 oz) 
      307B
      307C
      307D
      308C
      308D 
      277-8667  60 ± 5 mL (2.0 ± 0.2 oz) 
      307E2
      308E2 
      422-0868  60 ± 5 mL (2.0 ± 0.2 oz) 
      433-3881
      311
      311B
      311C
      311D
      311F
      312
      312B
      312C
      312D
      312D2
      312E
      313B
      313C
      313D
      314C
      314E 
      4I-7337  150 ± 15 mL (5.1 ± 0.5 oz) 
      313D2
      315
      315B
      315C
      315D
      317
      317B
      318B
      318C
      318D
      318D2
      318E
      319C
      319D
      320
      320B
      320C
      320D
      320D2
      320E
      321C
      321D
      323D
      323D2
      323F
      325F
      MD5075
      MD5075C
      MD5150
      MD5150C 
      248-7143  180 ± 20 mL (6.1 ± 0.7 oz) 
      538B  386-4139  180 ± 20 mL (6.1 ± 0.7 oz) 
      320
      325 
      102-8155  380 ± 20 mL (12.8 ± 0.7 oz) 
      320B
      320C
      322C
      323D
      324D
      325B
      325C
      325D
      329D 
      115-3696  380 ± 20 mL (12.8 ± 0.7 oz) 
      322B
      322C
      324D
      326D 
      115-6337  260 ± 15 mL (8.8 ± 0.5 oz) 
      322C  194-1130  260 ± 15 mL (8.8 ± 0.5 oz) 
      325D  239-3690  380 ± 20 mL (12.8 ± 0.7 oz) 
      328D
      330
      330B
      330C
      330D
      336D
      336D2
      336E
      340D
      340D2
      MD6240
      MD6290 
      136-2422  555 ± 30 mL (18.8 ± 1.0 oz) 
      330  102-8152  555 ± 30 mL (18.8 ± 1.0 oz) 
      330D  239-3691  555 ± 30 mL (18.8 ± 1.0 oz) 
      312D2
      330C
      330D
      345B
      345C
      345D
      349E
      349D
      568
      MD6420
      MD6420B
      MD6420C 
      248-7151  600 ± 30 mL (20.3 ± 1.0 oz) 
      345B
      345C
      345D
      349D 
      297-9264  500 ± 25 mL (16.9 ± 0.8 oz) 
      350  135-8903  600 ± 30 mL (20.3 ± 1.0 oz) 
      352F  357-7559  500 ± 25 mL (16.9 ± 0.8 oz) 
      365B
      365C 
      136-2429  1300 ± 65 mL (44.0 ± 2.2 oz) 
      365B
      365C 
      248-7256  1200 ± 60 mL (40.6 ± 2.0 oz) 
      374D
      374F
      365C
      365CL
      365B
      365BL
      MD6640
      MD6540
      MD6540C 
      340-8250  1100 ± 55 mL (37.2 ± 1.9 oz) 
      375
      5080 
      135-8904  1300 ± 65 mL (44.0 ± 2.2 oz) 
      385B
      385C
      5090 
      194-1157  1300 ± 65 mL (44.0 ± 2.2 oz) 
      385B
      385C
      5090 
      248-7257  1100 ± 55 mL (37.2 ± 1.9 oz) 
      390D
      390F 
      248-7257
      340-8242 
      1100 ± 55 mL (37.2 ± 1.9 oz) 
      5110B  121-7351  2400 mL (81.2 oz) 
      6015B  430-4139  2150 mL (73.1 oz) 

  21. Apply 9S-3263 Thread Lock Compound to and install the plug into the oil cavity of the idler.


    Illustration 26g02021921

  22. Gently 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.

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