Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals {4159, 4180} Caterpillar

Pipelayer

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

561M (S/N: 1KW1-UP)

561N (S/N: TAD1-UP; CPH1-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)

583T (S/N: CMX1-UP)

587R (S/N: BXL1-UP)

587T (S/N: FAT1-UP)

PL61 (S/N: RB71-UP; FNZ1-UP)

PL72 (S/N: P721-UP; P731-UP)

PL83 (S/N: CB21-UP; KSD1-UP; DLW1-UP)

PL87 (S/N: TEC1-UP; ZAC1-UP; KKJ1-UP)

Track-Type Skidder

527 (S/N: JSR1-UP; PTR1-UP; 2RS1-UP; 3DS1-UP; 4NS1-UP; BDW1-UP)

D4 TSKH Series II (S/N: 8ZF1-UP)

D4 TSKH Series III (S/N: 7PK1-UP)

D5 TSKH Series II (S/N: 7EG1-UP)

Track-Type Tractor

D10N (S/N: 2YD1-UP; 3SK1-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: AMA1-UP; GEB1-UP; TPB1-UP; DDD1-UP; MDG1-UP; JEL1-UP; RAL1-UP; JNS1-UP)

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

D4H Series III (S/N: 8PJ1-UP; 9GJ1-UP; 4NK1-UP)

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

D5H Series II (S/N: 8RJ1-UP)

D5M (S/N: 6GN1-UP; 3CR1-UP; 3DR1-UP; 4BR1-UP; 7LR1-UP; 4JS1-UP; 5ES1-UP; 5FS1-UP; 6AS1-UP)

D5N (S/N: AKD1-UP; AGG1-UP; CFH1-UP; CKT1-UP)

D5R (S/N: D5L1-UP; D5X1-UP)

D5R2 (S/N: R5A1-UP; WRE1-UP; WDZ1-UP)

D6 (S/N: RDC1-UP; HNK1-UP; RBP1-UP; KMT1-UP; KEW1-UP; KTW1-UP)

D6 XE (S/N: B721-UP; ES91-UP; LNC1-UP; HMH1-UP; HZL1-UP; D5M1-UP)

D6H (S/N: 8KB1-UP; 4RC1-UP; 6FC1-UP; 7PC1-UP; 8FC1-UP; 8YC1-UP; 3ZF1-UP; 5HF1-UP; 6CF1-UP; 3YG1-UP; 1FJ1-UP; 7ZK1-UP)

D6H Series II (S/N: 1KD1-UP; 2KD1-UP; 3ED1-UP; 4YF1-UP; 2TG1-UP; 4GG1-UP; 4LG1-UP; 8ZJ1-UP; 9KJ1-UP; 2DK1-UP; 5KK1-UP; 6CK1-UP; 8KK1-UP; 8SK1-UP; 9LK1-UP; 9RK1-UP; 1YL1-UP; 2BL1-UP; 2TL1-UP)

D6K (S/N: 6S61-UP; 7P61-UP; MP71-UP)

D6K2 (S/N: JTR1-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: MG51-UP; GB61-UP; DJA1-UP; PBA1-UP; CBF1-UP; CCG1-UP; ALH1-UP; JAH1-UP; CBJ1-UP; CCK1-UP; CBL1-UP; AKM1-UP; ALR1-UP; LJR1-UP; PER1-UP; CCS1-UP; GHS1-UP; MLW1-UP; P5W1-UP; ALY1-UP; DJY1-UP)

D6R (S/N: A6M1-UP; 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; D6R1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; S6T1-UP; 1RW1-UP; S6X1-UP; S6Y1-UP; C6Z1-UP)

D6R Series II (S/N: BNC1-UP; AFD1-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)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6R2 (S/N: PPP1-UP; SSS1-UP; TTT1-UP)

D6T (S/N: 2D21-UP; 2B31-UP; MB51-UP; AK71-UP; MH71-UP; 7C91-UP; 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; SNK1-UP; JML1-UP; KJL1-UP; SKL1-UP; JNM1-UP; TSM1-UP; WLM1-UP; K1R1-UP; PLR1-UP; GCT1-UP; HYT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; NDY1-UP; PEZ1-UP; SGZ1-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; 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)

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

D8N (S/N: 9TC1-UP; 1XJ1-UP; 5TJ1-UP; 7TK1-UP)

D8R (S/N: JR81-UP; 7XM1-UP; 9EM1-UP; 6YZ1-UP)

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

D8T (S/N: AW41-UP; JJ51-UP; J8B1-UP; MLN1-UP; FCT1-UP; KPZ1-UP)

D9L (S/N: 14Y1-UP)

D9N (S/N: 1JD1-UP; 5FJ1-UP; 6XJ1-UP)

D9R (S/N: JJB1-UP; HWH1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

D9T (S/N: TWG1-UP; RJS1-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 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 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

The following information is given to provide Disassembly and Assembly procedures for idlers with conventional Duo-Cone seals. The information in this bulletin should serve as an aid in determining whether an idler with conventional Duo-Cone seals can be reconditioned. During rebuild procedures, always correct any conditions which may have caused the original failure or wear.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599, "Undercarriage Reconditioning Guide Binder (Prescription 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 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 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.

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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.

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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

Disassembly

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Illustration 2	g02102144

1. Remove the plastic plug and the rubber stopper from the end of the shaft to drain the oil.
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   Illustration 3	g01577235

2. Remove the retainer bolts from the retainer on both sides of the idler.
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   Illustration 4	g01578333

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

   Note: Use approximately 22240 N to 66720 N (5000.0 lb to 15000.0 lb) of force to remove the collars.

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   Illustration 5	g02103055

4. Remove the retainer and the thrust washer from both sides of the idler.

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

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   Illustration 6	g01531253

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   Illustration 7	g02183514

5. Use 8T-0447 Dial Caliper As 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 the specifications.
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   Table 3

   Specifications for the End Collar
   Sales Model	Part Number of the End Collar	Inner Diameter (AA)
   D11N D11R D11T	156-4653	100.4 ± 0.02 mm (3.95 ± 0.001 inch)
   D10N D10R D10T	107-9620	74.4 ± 0.02 mm (2.93 ± 0.001 inch)
   D9N D9R D9T D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	107-3947	68.40 ± 0.02 mm (2.70 ± 0.001 inch)
   PL72	396-0581	58.4 ± 0.02 mm (2.30 ± 0.001 inch)
   D7E D7H D7R D6H D6R D6R2 D6T 572R 527	107-3945	58.4 ± 0.02 mm (2.30 ± 0.001 inch)
   D6K2	360-3534	54.05 ± 0.025 mm (2.12795 ± 0.00098 inch)
   D6M D6N D5H D5M D5N D5R D5R2 D4H 561H 561M 561N	160-9756	46.4 ± 0.02 mm (1.83 ± 0.001 inch)

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   Table 4

   Specifications for the Shaft
   Sales Model	Part Number of the Shaft	Diameter (BB)
   D11N D11R D11T	156-5351	100.5 ± 0.02 mm (3.96 ± 0.001 inch)
   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)
   D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	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 572R	131-3935	58.5 ± 0.02 mm (2.30 ± 0.001 inch)
   PL72	395-4327	58.5 ± 0.02 mm (2.30 ± 0.001 inch)
   527	160-9359	58.5 ± 0.02 mm (2.30 ± 0.001 inch)
   D6K2	248-5327	48.67 ± 0.13 mm (1.91614 ± 0.005 inch)
   D6H D6R D6R2 D6T	149-2494	58.5 ± 0.02 mm (2.30 ± 0.001 inch)
   D6M D6N D5H D5R D5R2	161-7350	46.5 ± 0.02 mm (1.83 ± 0.001 inch)
   D5M D5N D4H 561H 561M 561N	160-9757	46.5 ± 0.02 mm (1.83 ± 0.001 inch)

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   Illustration 8	g01578377

6. Remove the large O-ring seals from each retainer assembly.
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   Illustration 9	g01578378

7. Remove the O-rings from each end collar assembly.
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   Illustration 10	g01579126

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   Illustration 11	g01579128

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

9. 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.

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   Illustration 12	g01579134

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

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

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

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

    Clearance Between the Shaft and the Bearing
    Sales Model	Clearance Minimum/Maximum
    D11N D11R D11T	0.49 mm to 0.61 mm (0.019 inch to 0.024 inch)
    D10N D10R D10T D9N D9R D9T D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87 D7E D7H D7R 572R	0.44 mm to 0.56 mm (0.017 inch to 0.022 inch)
    D6K2	0.355 mm to 0.465 mm (0.014 inch to 0.018 inch)
    D6H D6R D6R2 D6T 527	0.30 mm to 0.40 mm (0.012 inch to 0.016 inch)
    D6M D6N D5H D5R D5R2	0.30 mm to 0.52 mm (0.012 inch to 0.020 inch)
    D5M D5N D4H 561H 561M 561N	0.26 mm to 0.48 mm (0.010 inch to 0.019 inch)
    PL72	0.24 mm to 0.46 mm (0.00945 inch to 0.01811 inch)

    Note: Table 6 and Table 7 include the dimensions to determine the clearance between the shaft and the bearing dimensionally. 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 idler shaft.

    Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8586, "Removal, Installation, and Conditioning of Idler Bearings and Track Roller Bearings".

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    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)
    D11N D11R D11T	187-1011	187-1007	168.89 ± 0.04 mm (6.649 ± 0.002 inch)	402.00 ± 0.13 mm (15.827 ± 0.005 inch)	258-4614	162.82 ± 0.03 mm (6.410 ± 0.001 inch)
    	367-3419
    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)
    	332-6008
    D9N D9R D9T	7T-2770	9W-4468	133.32 ± 0.04 mm (5.249 ± 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)
    	359-9579	359-9578
    D8N D8R D8T 583R 583T 587R 587T PL83 PL87	6Y-0553	6Y-0552	133.32 ± 0.04 mm (5.249 ± 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)
    D8L D8N D8R D8T 578	6Y-0556	6Y-0555	133.32 ± 0.04 mm (5.249 ± 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 (5.249 ± 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)
    	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)
    	192-0219	192-0218	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)
    	195-9816	195-9817	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)
    572R	192-0215	192-0214	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)
    	192-0219	192-0218	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)
    	195-9816	195-9817	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)
    D6K2	368-9792	362-8317	89.52 ± 0.13 mm (3.52 ± 0.005 inch)	159.86 ± 1 mm (6.29 ± 0.04 inch)	243-5321	91.52 ± 0.03 mm (3.60 ± 0.002 inch)
    	358-8556	354-0172	91.685 ± 0.015 mm (3.60964 ± 0.00059 inch)	159.85 mm (6.29329 inch)	243-5321	91.52 ± 0.03 mm (3.60 ± 0.002 inch)
    D6H D6R D6R2 D6T	202-4303	202-4302	114.28 ± 0.04 mm (4.499 ± 0.002 inch)	199.00 ± 0.13 mm (7.83 ± 0.005 inch)	9P-2245	108.06 ± 0.02 mm (4.254 ± 0.001 inch)
    	323–1171	321-8475	114.28 ± 0.04 mm (4.49 ± 0.00157 inch)	199.05 ± 0.13 mm (7.83660 ± 0.00512 inch)	9P-2245	108.06 ± 0.02 mm (4.25432 ± 0.0008 inch)
    	202-4295	202-4294	114.28 ± 0.04 mm (4.499 ± 0.002 inch)	199.00 ± 0.13 mm (7.83 ± 0.005 inch)	9P-2245	108.06 ± 0.02 mm (4.254 ± 0.001 inch)
    PL72	395-4270	395-4269	114.28 ± 0.04 mm (4.499 ± 0.002 inch)	199.00 ± 0.13 mm (7.83 ± 0.005 inch)	398-1067	108.06 ± 0.02 mm (4.254 ± 0.001 inch)
    527	202-4295	202-4294	114.28 ± 0.04 mm (4.499 ± 0.002 inch)	199.00 ± 0.13 mm (7.83 ± 0.005 inch)	9P-2245	108.06 ± 0.02 mm (4.254 ± 0.001 inch)
    D6M D6N D5H D5R D5R2	190-1547	190-1548	102.00 ± 0.04 mm (4.016 ± 0.002 inch)	189.00 ± 0.13 mm (7.441 ± 0.005 inch)	9P-1360	95.84 ± 0.08 mm (3.773 ± 0.003 inch)
    D5M D5N D4H	190-1536	193-5929	96.00 ± 0.04 mm (3.780 ± 0.002 inch)	168.00 ± 0.13 mm (6.614 ± 0.005 inch)	8P-7002	89.67 ± 0.08 mm (3.530 ± 0.003 inch)
    D5M D5N D4H 561H 561M 561N	190-2495	193-5930	96.00 ± 0.04 mm (3.780 ± 0.002 inch)	168.00 ± 0.13 mm (6.614 ± 0.005 inch)	8P-7002	89.67 ± 0.08 mm (3.530 ± 0.003 inch)

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    Table 7

    Specifications for the Shaft
    Sales Model	Idler Assembly	Shaft	Outside Diameter of the Shaft	Length of the Bearing Surface
    D11N D11R D11T	187-1011	156-5351	162.27 ± 0.03 mm (6.389 ± 0.001 inch)	377.00 ± 0.10 mm (14.842 ± 0.004 inch)
    	367-3419
    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)
    	332-6008
    D9N D9R D9T	7T-2770	154-3309	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	265.00 ± 0.10 mm (10.433 ± 0.004 inch)
    	359-9579
    D8N D8R D8T 583R 583T 587R 587T PL83 PL87	6Y-0553	154-3307	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	225.00 ± 0.10 mm (8.858 ± 0.004 inch)
    D8L D8N D8R D8T 578	6Y-0556	154-3307	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	225.00 ± 0.10 mm (8.858 ± 0.004 inch)
    D7E	192-0223	351-8927	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    D7H D7R	192-0215	131-3935	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    	192-0223	131-3935	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    	192-0219	131-3935	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    	195-9816	131-3935	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    572R	192-0215	131-3935	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    	192-0219	131-3935	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    	195-9816	131-3935	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
    D6R	323-1171	149-2494	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.299 ± 0.002 inch)
    D6H D6R D6R2 D6T	202-4303	149-2494	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.299 ± 0.002 inch)
    	202-4295	149-2494	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.299 ± 0.002 inch)
    D6K2	368-9792	248-5327	53.92 ± 0.025 mm (2.123 ± 0.001 inch)	253.2 ± 0.5 mm (9.969 ± 0.02 inch)
    	358-8556
    PL72	395-4326	395-4327	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.299 ± 0.002 inch)
    527	202-4295	160-9359	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.299 ± 0.002 inch)
    D6M D6N D5H D5R	190-1546	161-7350	95.43 ± 0.03 mm (3.757 ± 0.001 inch)	150.00 ± 0.10 mm (5.906 ± 0.004 inch)
    D5M D5N D4H	190-1536	160-9757	89.30 ± 0.03 mm (3.516 ± 0.001 inch)	129.00 ± 0.10 mm (5.079 ± 0.004 inch)
    D5M D5N D4H 561H 561M 561N	190-2495	160-9757	89.30 ± 0.03 mm (3.516 ± 0.001 inch)	129.00 ± 0.10 mm (5.079 ± 0.004 inch)

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    Illustration 14	g01579193

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

12. Wash all components to remove debris from the components.
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    Illustration 15	g01579194

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

Assembly

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Illustration 16	g01582733

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Illustration 17	g01582734

1. Apply 1U-6395 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.

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   Illustration 18	g01583933

2. Inspect each set of 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.

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   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.

   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.
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   Table 8

   Duo-Cone Seal Installation Tool
   Sales Model	Part Number
   D11N D11R D11T	159-9843
   D10N D10R D10T	129-1340
   D9N D9R D9T D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	227-4755
   D7E D7H D7R 572R D6H D6R D6R2 D6T 527 PL72	136-6813
   	224-9467
   D6K2	9U-7537
   D6M D6N D5H D5M D5N D5R D4H 561H 561M 561N	179-7208

5. Lightly dampen the lower half of the toric ring with isopropyl alcohol.
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   Illustration 19	g01584679

6. Use a firm, even pressure on the installation tool to install the Duo-Cone seal in the end collar.
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   Illustration 20	g02140680

7. Use a firm, even pressure on the installation tool to install the Duo-Cone seal in the retainer.
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   Illustration 21	g01584856

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   Illustration 22	g01584858

8. Use 8T-0447 Dial Caliper As to check the height of the assembled Duo-Cone seals in the retainers and the end collars. Take measurements at four 90 degree 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 8C-3698 Oil.
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   Illustration 23	g01584895

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.

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    Illustration 24	g01584954
    The thrust ring is pinned onto the retainer.

    Note: If pinned thrust washers were used, then install the thrust washers 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.

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    Illustration 25	g01258662
    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.
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    Illustration 26	g01584957

12. Slide the retainer assembly over the shaft and carefully move the retainer to the final position.
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    Illustration 27	g01584958

13. Use 5P-3931 Anti-Seize Compound on Bolt Threads.Tighten the retainer bolts.

14. Torque the retainer bolts to the specifications in Table 9.
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    Table 9

    Sales Model	Bolt Torque
    D11N D11R D11T	270 ± 40 N·m (199.1 ± 29.5 lb ft)
    D10N D10R D10T	135 ± 20 N·m (99.6 ± 14.8 lb ft)
    D9N D9R D9T D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87 D7E D7H D7R 572R	85 ± 15 N·m (62.7 ± 11.1 lb ft)
    D6H D6K2 D6R D6R2 D6T D6M D6N D5H D5M D5N D5R D4H 561H 561M 561N 527 PL72	55 ± 10 N·m (40.6 ± 7.4 lb ft)

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    Illustration 28	g02182654

15. Check for end play prior to the end collar installation. Refer to Table 10 for the correct end play specifications.
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    Illustration 29	g02182715

16. Use the 8T-5096 Dial Indicator Test Group or equivalent tool. Install the magnetic base onto the face of the retainer assembly. Adjust the arms and the indicator as shown.
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    Illustration 30	g02182777

17. The contact point of the dial indicator needs to engage the idler shaft.
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    Illustration 31	g02182855

18. 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.
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    Illustration 32	g02182845

19. 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.
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    Table 10

    Sales Model	End Play Minimum to Maximum
    D11N D11R D11T D10N D10R D10T	0.23 mm to 1.29 mm (0.010 inch to 0.051 inch)
    D9N D9R D9T D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	0.33 mm to 1.19 mm (0.013 inch to 0.047 inch)
    D7E D7H D7R 572R D6M D6N D5H D5M D5N D5R D4H 561H 561M 561N	0.38 mm to1.24 mm (0.015 inch to 0.049 inch)
    D6K2	0.27 mm to 1.55 mm (0.01063 inch to 0.06102 inch)
    D6H D6R D6R2 D6T 527 PL72	0.25 mm to 1.25 mm (0.010 inch to 0.050 inch)

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

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    Illustration 33	g01585593

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    Illustration 34	g01585594

20. 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 .
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    NOTICE
    Never permit oil to get on the toric rings or ramps before both seal rings are put together in their final assembled position.

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    Illustration 35	g01585595

21. 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: To 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.

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    Illustration 36	g01585596

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    Illustration 37	g01585597

22. Position the end collar on the shaft. Use the correct tooling and a hydraulic press to install the end collar. Refer to Table 11 for the correct tooling to install the end collar.

    Note: Approximately 22240 N (5000.0 lb) is required to install the end collar.

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    Table 11

    Tooling for End Collar
    Sales Model	Part Number
    D11N D11R D11T	170-5405
    D10N D10R D10T	170-5406
    D9N D9R D9T	170-5409
    D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	170-5408
    D7E D7H D7R 572R	170-5411
    D6H D6R D6R2 D6T 527 PL72	170-5412
    D6M D6N D5H D5R	201-1581
    D5M D5N D4H 561H 561M 561N	201-1582

23. Repeat Step 22 to install the other end collar.
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    Illustration 38	g01585598

24. 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.
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    Table 12

    Spin Socket Tooling
    Sales Model	Part Number
    D11N D11R D11T	1U-3999
    D10N D10R D10T	FT1909
    D9N D9R D9T D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	FT1910
    D7E D7H D7R 572R D6H D6R D6R2 D6T 527 PL72	FT1911
    D6M D6N D5H D5M D5N D5R D4H 561H 561M 561N	FT1994

25. 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 Table13 for the correct installer tool. The stopper must be installed 7 mm ± 7 mm (0.3 inch ± 0.3 inch) below the surface of the shaft.
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    Table 13

    Installer Tool Group
    Sales Model	Part Number
    D11N D11R D11T	228-0603
    D10N D10R D10T D9N D9R D9T D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	228-0600
    D7E D7H D7R 572R D6H D6R D6R2 D6T 527 PL72	228-0597
    D6M D6N D5H D5M D5N D5R D4H 561H 561M 561N	394-9580

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    Illustration 39	g01585599

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    NOTICE
    Do not allow a surge of air to enter the idler and do not use pressure more than 138 kPa (20.0 psi), as this surge of air may damage the seals.

26. Use 170-5664 Test and Fill Cart Gp to evaluate and fill the idler.
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    Illustration 40	g01585600

27. 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 3.4 kPa (0.50 psi) or less is acceptable.

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

    Sales Model	Oil Volumes	Recommended Oil
    D11N D11R D11T	1650 ± 80 mL (56.0 ± 3.0 oz)	Cat FDOA SYN oil
    D10N D10R D10T	825 ± 40 mL (28.0 ± 1.4 oz)
    D9N D9R D9T	775 ± 40 mL (26.2 ± 1.4 oz)	8C-3698 SAE 30
    D8L D8N D8R D8T 578 583R 583T 587R 587T PL83 PL87	600 ± 30 mL (20.3 ± 1.0 oz)
    D6K2	600 ± 50 mL (20.3 ± 1.0 oz)
    	330 ± 15 mL (11.16 ± 0.5 oz)
    D7E D7H D7R 572R	650 ± 15 mL (22.0 ± 0.5 oz)
    D6H D6R D6R2 D6T 527 PL72	540 ± 15 mL (18.3 ± 0.5 oz)
    D6M D6N D5H D5R	440 ± 10 mL (14.9 ± 0.3 oz)
    D5M D5N D4H 561H 561M 561N	362 ± 10 mL (12.2 ± 0.3 oz)

    Note: Refer to table 15 for D10N, D10R, D10T, D11N, D11R, D11T

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    Table 15

    Cat FDAO Syn Part Numbers
    Liters
    18 L	208 L
    206-5211	206-5212
    Gallons
    5 gal	55 gal
    208-2390	198-7450

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    Illustration 41	g01585603

29. 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.

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    Illustration 42	g01585604

30. 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.