Reconditioning Procedure for Seal Ramps on Inverted Style Idler and Roller Shafts {0729, 4150, 4154, 4159, 6433, 7561} Caterpillar


Reconditioning Procedure for Seal Ramps on Inverted Style Idler and Roller Shafts {0729, 4150, 4154, 4159, 6433, 7561}

Usage:

D6D 01Y
Excavator
All Custom Product and CIPI Applications
Forest Products
All
Pipelayer
All
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
D3C - D5C Series III

Introduction

Table 1
Revision  Summary of Changes in SEBF8597 
06–09  Added serial number prefixes for New Product Introduction. 
05  Added Safety Section. 

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Undercarriage Reconditioning Bulletin contains the necessary information in order to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made in order to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Undercarriage Reconditioning Bulletin must be used with the latest technical information that is available from Caterpillar.

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

Summary

Caterpillar designed inverted idler and roller shafts with a seal ramp surface roughness, which allows toric rings to grip the shaft and apply the proper seal face loading. The toric rings act as a spring keeping pressure between the two Duo-Cone Seal faces as the shaft moves from end play. A smooth surface allows toric rings to slip on the shaft resulting in uneven seal alignment and low seal face loading. Low seal face loading causes a poor seal and eventual component failure. This bulletin defines the process to be used to blast seal ramps on inverted style shafts to regain surface finish. A reconditioned seal ramp saves the cost of a new shaft, and prevents oil leaks in rollers and idlers.



Illustration 1g02341536
(1) Bearing Surface
(2) Seal Ramp Surface
(3) Mounting Surface
(4) Thrust Face

References

Reference: Special Instructions, SEBF8599, "Undercarriage Reconditioning Guide"

Reference: Special Instructions, SEBF8596, "Guideline for Reusable Roller & Idler Components"

Reference: Special Instructions, SEBF8581, "Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-Cone Seals"

Reference: Special Instructions, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals"

Safety



Illustration 2g02139237

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

This bulletin may contain hazardous steps. Hazardous steps will be identified by warning symbols like the ones.

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.

Tooling and Equipment

Table 2
Bearing Sleeves 
Part Number  Sleeve Diameter
(mm) 
Idler  Roller 
197-8122  96
(mm) 
D4H, D5H  D4H, D5H , 953, 943, 939 
197-8123  108
(mm) 
D5H, D6H/R/N, 517, 527  D6H, 963 
196-9559  114.5
(mm) 
D7H, D8R/N/L, D9N/R, 578, 579, 973 
197-8124  127
(mm) 
D7R/N/H, D8L/R/N, D9R/N, 578  D9L, D10R/L, 589 
197-8125  136
(mm) 
D9L, D10R/N, 589  D10L, D11N/R 
197-8126  163
(mm) 
D10L, D11N/R 

Table 3
End Sleeves 
Part Number  Sleeve Diameter
(mm) 
Idler  Roller 
196-9554  45
(mm) 
D4H, D5H  D4H, D5H, 939, 943, 953 
196-9558  58
(mm) 
D5H, D6H/R/N, D7H/R/N, D8R/N/L, 517, 527  D6H, D7H, D9R/N, 578, 579, 963, 973 
196-9557  68
(mm) 
D8R/N/L, D9R/N, 578  D9L, D10N/R, 589 
196-9556  74
(mm) 
D9L, D10N/R, 589  D10L, D11R/N 
196-9555  100
(mm) 
D10L, D11R/N 

Table 4
Blast Cabinet Tooling 
Part Number  Description 
196-9552  Frame Assembly 
196-9553  Wheels 

Blast Procedure

Clean and Inspect

  1. Remove the shaft from the roller or idler group. Refer to Undercarriage Reconditioning Bulletin, SEBF8581, "Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-Cone Seals" and Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-cone seals".

  2. Clean all contamination from the shaft.

  3. Inspect the shaft for reusability using Undercarriage Reconditioning Bulletin, SEBF8596, "Guideline for Roller & Idler Component Reuse".

  4. Inspect the seal ramp for a toric groove or any smooth portions of the seal-ramp area.


    Illustration 3g02339282
    Smooth seal ramp, needs conditioning


    Illustration 4g02339378
    Conditioned seal ramp

  5. Ifthe seal ramp area, has no toric ring groove or smooth spots refer to Undercarriage Reconditioning Bulletin, SEBF8581, "Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-Cone Seals" and Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals"

  6. If the seal ramp is smooth from toric ring wear (refer to illustration 3), the following blast procedure will guide reconditioning steps to return the ramp area to a Ra value of 5.00 - 8.75 µm (197 - 345) µin.

Blast Preparation

Caterpillar recommends the use of a siphon (gravity) fed blasting machine or a pressure blasting machine system with the following specifications:

  1. Air pressure regulated to 552 kPa (80 psi) to 621 kPa (90 psi).

    Note: During the blasting process the air pressure must hold to 552 kPa (80 psi) to 621 kPa (90 psi). If not, a larger air supply must be used. 25-30 cubic feet per minute of air is recommended. Dry air is required to operate a blasting system that contains Aluminum Oxide.

  2. 127 mm (5/32 inch) tungsten carbide blasting tip.

  3. Recommended blasting media is 14-16 grit Aluminum Oxide.

  4. Blasting cabinet that accommodates all sizes of inverted style shafts.


Illustration 5g02339469

Sand Blast Procedure

Protect the shaft

  1. Cover the stopper hole and both oil cross-holes with duct tape to prevent dust and blasting media from contaminating the oil cavity.


    Illustration 6g02339484
    Tape over cross hole and stopper hole

  2. Slide the recommended sleeves (refer to Tables 2 and 3) over the bearing surface and the mounting diameter of the shaft to protect the shaft from blasting tip overspray.


Illustration 7g02339498
Protective sleeves


Illustration 8g02339509
Installation of protective sleeves

Blasting

  1. Place the shaft on the rolling device (refer to Table 4) inside the blasting cabinet and confirm that the shaft will roll without interference.


    Illustration 9g02339538
    Smoothly roll shaft

  2. Set the air pressure to 552 kPa (80 psi) to 621 kPa (90 psi).


    Illustration 10g02339556
    Regulator at 85 psi

  3. Use 14 - 16 grit size Aluminum Oxide.

  4. Ensure that the feed line is outfitted with 127 mm (5/32 inch) tungsten carbide blasting tip.


    NOTICE

    Ensure that the Aluminum Oxide and the blasting tip retain original diameters. Aluminum Oxide breaks down with use and must remain a constant 14 - 16 grit size in order to gain proper surface finish. Over time, the blasting tip will wear and become larger causing lower velocity of blasting particles and a drop in air pressure.


  5. With all safety devices in place, hold the blasting tip above the ramp area 25.4 ± 12.7 mm (1 ± 0.5 inch).

  6. Begin blasting perpendicular to the ramp surface while rotating the shaft using fluid motions for 1.5 minutes (5 to 7 revolutions). A uniform surface roughness should be observed.


Illustration 11g02339598
Blasting tip 1 inch perpendicular to ramp area


NOTICE

Although protective covers are in place on the shaft, concentrate the blast spray on the exposed seal ramp area only. Blasting the protective covering will cause deterioration of the cover. Deterioration of the cover may lead to damage of the thrust face and bearing surface finish, in which case the shaft cannot be reused.


Clean up, Final Inspection, Validate Surface Finish

  1. Remove the shaft from the blast cabinet.

  2. Inspect the bearing surface and thrust face for blast pitting after the protective sleeves have been removed.


    Illustration 12g02339617
    Smooth bearing and thrust surfaces

  3. Peel the tape away from the cross-hole and stopper hole.

  4. Validate the surface roughness of the seal ramp area using a profilometer (roughness indicator). The Roughness Average (Ra) value of the seal ramp area should be 5.00 - 8.75 µm (197 - 345) µin. A cut-off length of 0.8 mm (0.03 inch) should be used.


    Illustration 13g02339658
    Profilometer on seal ramp area

  5. Clean the shaft thoroughly in a parts washer or solvent tank. Cleaning the shaft will free the shaft of tape adhesive or any blast debris that could cause contamination.

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