Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals {4159, 7561, 7561} Caterpillar

Excavator

LL231 (S/N: 8PD1-UP)

Pipelayer

578 (S/N: 8HB1-UP)

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

589 (S/N: 31Z1-UP)

Track-Type Loader

939 (S/N: 9GL1-UP)

943 (S/N: 31Y1-UP; 63Y1-UP; 73Y1-UP; 04Z1-UP; 19Z1-UP)

953 (S/N: 63Y1-UP; 73Y1-UP; 76Y1-UP; 77Y1-UP; 78Y1-UP; 05Z1-UP; 20Z1-UP; 44Z1-UP)

953B (S/N: 5MK1-UP)

963 (S/N: 29S1-UP; 43Y1-UP; 06Z1-UP; 11Z1-UP; 18Z1-UP; 21Z1-UP; 48Z1-UP)

963B (S/N: 9BL1-UP)

973 (S/N: 11B1-UP; 66G1-UP; 86G1-UP; 91L1-UP; 26Z1-UP; 32Z1-UP)

Track-Type Tractor

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

D10N (S/N: 3SK1-UP)

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

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

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

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

D4H Series III (S/N: 4NK1-UP)

D5H (S/N: 7NC1-UP; 8RC1-UP; 8SC1-UP; 9HC1-UP; 1DD1-UP; 1YD1-UP; 2SD1-UP; 3MD1-UP; 4KD1-UP)

D5H Series II (S/N: 8RJ1-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; 3YJ1-UP)

D6H Series II (S/N: 1KD1-UP; 2KD1-UP; 3ED1-UP; 4YF1-UP; 2TG1-UP; 4GG1-UP; 4LG1-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; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; S6T1-UP; S6X1-UP; S6Y1-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)

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: 7XM1-UP; 9EM1-UP)

D9L (S/N: 14Y1-UP)

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

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

Introduction

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

The following information is given to provide Disassembly and Assembly procedures for idlers with inverted Duo-Cone seals.

The information in this bulletin should serve as an aid in determining whether an idler with inverted Duo-Cone seals can be reconditioned. During rebuild procedures, always correct any conditions which may have caused the original failure or wear and never install a component that falls within the “Do not use again” criteria.

References

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

Reference: Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers"

Reference: Special Instruction, SEHS8483, "Assembly and Installation of Inverted Duo-Cone Seals"

Reference: Special Instruction, SEHS8974, "Tool and Specification Chart for Inverted Duo-Cone Seals"

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit FT2724"

Safety

Illustration 1	g02139237

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

This bulletin may contain hazardous steps. A safety alert symbol like the one below is used to call attention to 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.

Tooling and Equipment

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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.

Disassembly

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Illustration 2	g02409476
Remove plug and stopper.

1. Drill out the stopper from the end of the pin shaft with a 0.5 inch drill bit to drain the oil.
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   Illustration 3	g02409477
   Remove bolts and retainers.

2. Remove the 6 to 12 bolts and the retainer assembly.
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   Illustration 4	g02409479
   Remove thrust washers.

3. Remove the thrust washers from each end of the idler.

   Note: Some thrust washers are pinned.

   Note: Refer to Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers" for the salvage procedures on retainers with damaged thrust washers.

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   Illustration 5	g02409480
   Remove retainer seal ring and o-ring from retainers.

4. Remove the retainer seal ring and o-ring from each retainer assembly.
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   Illustration 6	g02409481
   Remove the Duo-Cone seals from the idler shaft.

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   Illustration 7	g02409482
   Remove Duo-Cone seals from retainer assemblies.

5. Remove the Duo-Cone seals from the idler shaft and retainer assemblies. Inspect each set of seals side by side for reusability.

   Note: If the seals are reusable, the seals must be kept in matching pairs. Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals" for proper reuse information.

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   Illustration 8	g02409483
   Remove stabilizers.

6. Remove the toric stabilizers from both sides of the idler.
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   Table 3

   Shaft/Bearing Clearance
   Model Number	Clearance (min/max)
   D11R, D11N, D10L, D10R, D10N, D9L, D9R, D9N, 589, D8L, D8R, D8N, 578, D7R, D7H, 973	0.44/0.56 mm (0.0173/0.022iinch)
   D6H, 963, D5H, 953	0.33/0.52 mm (0.013/0.021 inch)
   D4H, 943	0.26/0.44 mm (0.010/0.017 inch)

7. Measure the shaft-to-bearing clearance using a feeler gauge. The clearance must fall within the specifications given in Table 3.
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   Table 4

   Idler Rebuild Dimensions
   Model	Idler Assembly	Idler Bore Diameter	Idler Hub Width	Bearing Part Number	Bearing and Idler Assembly Diameter
   D11N/ D11R	9W-9650 148-3730	168.89 ± 0.04 mm (6.650 ± 0.002 inch)	402.00 ± 0.13 mm (15.827 ± 0.005 inch)	9W-4195 148-3540	162.77 ± 0.03 mm (6.408 ± 0.001 inch)
   D10N/ D10R	7T-0961	142.85 ± 0.04 mm (5.624 ± 0.002 inch)	326.00 ± 0.13 mm (12.8345 ± 0.005 inch)	9W-4194	136.78 ± 0.03 mm (5.385 ± 0.001 inch)
   D10L	6Y-0216 7T-2175 9W-4340	168.89 ± 0.04 mm (6.650 ± 0.002 inch)	375.00 ± 0.13 mm (14.764 ± 0.005 inch)	9W-4195 P4-7838	162.77 ± 0.03 mm (6.408 ± 0.001 inch) 162.62 ± 0.02 mm (6.402 ± 0.001 inch)
   D9N/ D9R	7T-2770	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)
   D9L	9W-6037	142.85 ± 0.04 mm (5.624 ± 0.002 inch)	290.00 ± 0.13 mm (11.417 ± 0.005 inch)	9W-4194	136.78 ± 0.03 mm (5.385 ± 0.001 inch)
   D8N/ D8R	6Y-0553 (Rear)	133.32 ± 0.04 mm (5.250 ± 0.002 inch)	250.00 ± 0.13 mm (9.843 ± 0.005 inch)	9W-9499	127.25 ± 0.03 mm (5.010 ± 0.001 inch)
   	6Y-0556 (Front)	133.32 ± 0.04 mm (5.250 ± 0.002 inch)	250.00 ± 0.13 mm (9.843 ± 0.005 inch)	9W-9499 154-3298	127.25 ± 0.03 mm (5.010 ± 0.001 inch)
   D8L	6Y-0556	133.32 ± 0.04 mm (5.250 ± 0.002 inch)	250.00 ± 0.13 mm (9.843 ± 0.005 inch)	9W-9499 154-3298	127.25 ± 0.03 mm (5.010 ± 0.001 inch)
   D7N/ D7R	6Y-2030	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)
   	9W-7646	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)
   	6Y-2033	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)
   D7H	3Q-3873	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)
   D6N/ D6R/ D6H	7T-8940	114.28 ± 0.04 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)
   	6T-3217	114.28 ± 0.04 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)
   D5H	6T-1763	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)
   517	8E-4008	114.28 ± 0.04 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)
   D4H/D5M	6T-2615	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)
   	7T-4399	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)
   589	9W-6037	142.85 ± 0.04 mm (5.624 ± 0.002 inch)	290.00 ± 0.13 mm (11.417 ± 0.005 inch)	9W-4194	136.78 ± 0.03 mm (5.385 ± 0.001 inch)
   578	6Y-0556	133.32 ± 0.04 mm (5.250 ± 0.002 inch)	250.00 ± 0.13 mm (9.843 ± 0.005 inch)	9W-9499 154-3298	127.25 ± 0.03 mm (5.010 ± 0.001 inch)

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   Table 5

   Shaft Specifications
   CAT Model	Idler Assembly	Shaft Part Number	Outer Shaft Diameter	Bearing Surface Length
   D11N/ D11R	9W-9650 148-3730	6T-8660	162.27 ± 0.03 mm (6.389 ± 0.001 inch)	377.00 ± 0.05 mm (14.842 ± 0.002 inch)
   		153-9461	162.27 ± 0.03 mm (6.389 ± 0.001 inch)	377.00 ± 0.05 mm (14.842 ± 0.002 inch)
   		138-4331	162.27 ± 0.03 mm (6.389 ± 0.001 inch)	377.00 ± 0.10 mm (14.843 ± 0.004 inch)
   D10N/ D10R	7T-0961	7T-0955	136.28 ± 0.03 mm (5.365 ± 0.001 inch)	301.00 ± 0.05 mm (11.850 ± 0.002 inch)
   		128-9693	136.28 ± 0.03 mm (5.365 ± 0.001 inch)	301.00 ± 0.10 mm (11.850 ± 0.004 inch)
   D10L	6Y-0216 7T-2175 9W-4340	7G-2622	162.27 ± 0.03 mm (6.389 ± 0.001 inch)	350.00 ± 0.05 mm (13.800 ± 0.002 inch)
   		138-4330	162.27 ± 0.03 mm (6.389 ± 0.001 inch)	350.00 ± 0.10 mm (13.800 ± 0.004 inch)
   D9N/ D9R	7T-2770	7T-2778	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	265.00 ± 0.05 mm (10.433 ± 0.002 inch)
   		138-9378	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	265.00 ± 0.10 mm (10.433 ± 0.004 inch)
   D9L	9W-6037	3T-3617	136.28 ± 0.03 mm (5.365 ± 0.001 inch)	265.00 ± 0.05 mm (10.433 ± 0.002 inch)
   		140-0291	136.28 ± 0.03 mm (5.365 ± 0.001 inch)	265.00 ± 0.10 mm (10.433 ± 0.004 inch)
   D8N/ D8R	6Y-0556 6Y-0553	8P-6938	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	225.00 ± 0.05 mm (8.858 ± 0.002 inch)
   		138-9712	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	225.00 ± 0.10 mm (8.858 ± 0.004 inch)
   D8L	6Y-0556	8P-6938	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	225.00 ± 0.05 mm (8.858 ± 0.002 inch)
   		138-9712	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	225.00 ± 0.10 mm (8.858 ± 0.004 inch)
   D7N/ D7R/ D7H	6Y-2030 9W-7646 6Y-2033 3Q-3873	6Y-1756	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	191.00 ± 0.10 mm (7.520 ± 0.004 inch)
   D6N/ D6R/D6H	7T-8940	6T-3220	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.300 ± 0.002 inch)
   	6T-3217
   D6H	7T-8940	116-1422	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.300 ± 0.002 inch)
   	6T-3217
   D5H	6T-1763	6T-3285	95.43 ± 0.03 mm (3.757 ± 0.001 inch)	150.00 ± 0.05 mm (5.906 ± 0.002 inch)
   517/D5H	8E-4008	8E-4017	107.71 ± 0.03 mm (4.241 ± 0.001 inch)	160.00 ± 0.05 mm (6.300 ± 0.002 inch)
   D4H D5M	7T-4399	6T-2620	89.30 ± 0.03 mm (3.516 ± 0.001 inch)	129.00 ± 0.05 mm (5.079 ± 0.002 inch)
   	6T-2615
   589	9W-6037 9W-0621	3T-3617 140-0291	136.28 ± 0.03 mm (5.365 ± 0.001 inch)	265.00 ± 0.05 mm (10.433 ± 0.002 inch)
   578	6Y-0556	8P-6938 138-9712	126.75 ± 0.03 mm (4.990 ± 0.001 inch)	225.00 ± 0.05 mm (8.858 ± 0.002 inch)

   Note: Table 4 and Table 5 include the dimensions to determine the shaft-to-bearing clearance. The clearance can be checked dimensionally or with feeler gauges.

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   Illustration 9	g02409484
   Remove the shaft.

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   Illustration 10	g02409485
   Shaft with hoist attached.

8. Partially slide the shaft out of the idler. If necessary, attach a hoist to help remove the shaft the rest of the way.

Assembly

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NOTICE
Be sure to maintain the correct surface roughness of the shaft ramp area when removing debris from the idler shaft. Failure to maintain the integrity of this surface could lead to a failure in the idler.

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Illustration 11	g02409486
Factory finish for shaft ramp area.

1. Wash and remove all debris from the idler and all of the components.

2. Use alcohol to clean components with a lint free cloth.
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   Illustration 12	g02409487
   Install o-ring.

3. Use 369-9450 O-Ring Assembly Compound to install the new o-rings into the retaining grooves.
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   Illustration 13	g02409488
   Install seals into retainer.

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   Illustration 14	g02409489
   (1) Retainer

4. Lubricate the retainer seal ring o-rings with alcohol. Use the installation tool and an arbor press to insert the seal ring and o-ring into the retainer. Press the retainer seal in until the rubber o-ring is seated against the base of the retainer.
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   Illustration 15	g02409490
   Check retainer seal ring height.

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   Illustration 16	g02409491
   (A) Retainer seal ring height (1) Retainer (2) Retainer seal ring

5. Check the assembled seal ring height in the retainer at four locations 90 degrees apart. (Refer to Table 2 for proper seal height tooling.) The difference in height must not exceed 0.3 mm (0.01 inch). Also, turn the retainer over to ensure that the rubber o-ring is in contact all around the bottom of the base in the retainer.

6. Lightly lubricate the idler bearings with the same oil type used to fill the idler.
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   Illustration 17	g02409492
   Install shaft.

7. Install the shaft into the idler.
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   NOTICE
   Use care when installing the shaft in the idler. The shaft may scrape bronze particles from the bearing, the bronze particles will cause a failure in the idler.

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   Illustration 18	g02409493
   Install the toric stabilizers.

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   Illustration 19	g02409494
   (3) Shaft (4) Toric stabilizer

8. Install a toric stabilizer on each end of the shaft. Make sure that the toric stabilizers are installed on the shaft with the contoured edge facing the interior of the idler.
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   Illustration 20	g02409495
   Install thrust washers.

9. Install the thrust washers on both ends of the idler shaft.
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   Illustration 21	g02409497
   Assemble shaft seal. (5) Seal ring (6) Rubber Toric ring (7) Retaining lip (8) Seal ring ramp

10. When the Duo-Cone seals are being reused, install a new toric ring in the seal ring at the bottom of the seal ring ramp. Against the retaining lip.
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    NOTICE
    Be sure that the toric ring is properly positioned against the retaining lip around the entire circumference of the seal ring. Verify the toric position for new Duo-Cone seals. Failure to do so may result in a failure of the idler.

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    Illustration 22	g02409499
    Install Duo-Cone seals onto shaft.

11. Use the correct installation tool to install the Duo-Cone seals onto the idler shaft. (Refer to Table 2 for proper seal installer.) Use even pressure and a slight twisting motion to slide the toric and seal ring down the shaft until the tooling touches the shaft end.
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    Illustration 23	g02409501
    Check seal height on the shaft.

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    Illustration 24	g02409502
    (B) Seal height (9) Duo-Coneseal (10) Shaft thrust face

12. Check the assembled Duo-Cone seal height from the shaft thrust face at four locations 90 degrees apart. (Refer to Table 2 for proper seal height tooling.) The difference in height around the seal must not exceed 0.8 mm (0.032 inch).

    Note: If the seal height specification is not met, the Duo-Cone seals must be removed and reinstalled.

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    Illustration 25	g02409504
    Clean shaft seal ring.

13. Wipe the shaft seal ring face with a lint free cloth.

    Note: To reduce the risk of introducing airborne contaminants to the face of the Duo-Cone seal ring, minimize the time between seal ring oil application and assembly of the retainer to the idler assembly.

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    NOTICE
    Do not apply oil with contaminated fingers, gloves, or brushes.

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    Illustration 26	g03009037

14. Use a pneumatic dispenser, squeeze bottles or tubes, or syringes to apply oil to the entire face of the seal rings.
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    Illustration 27	g02409506
    Clean retainer seal face.

15. Wipe the entire retainer seal face with a lint free cloth.
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    Table 6

    Alignment Sleeve Tooling
    Model	Tooling Part Number
    D11N, D11R	8T-0825
    D10, D10N, D10R, 589, D9L	8T-0824
    D9N, D9R, D8L, D8N, D8R, 578	8T-0823
    D7H, 973, 973 Steel Mill, D6H, D6R, 963, 963B	8T-0822
    D5H, 953, D4H, 943	8T-0945

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    Illustration 28	g02409507
    Slide on retainer.

16. Slip the retainer assembly over the shaft and carefully move the alignment sleeve and the retainer onto the idler. (Refer to Table 6 for correct alignment sleeve.)
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    Illustration 29	g02409508
    Install two retainer bolts ( threaded guide-rods optional).

17. Apply an even pressure to the alignment sleeve, at the same time, starting two bolts 180 degrees apart. Tighten the bolts in an alternating fashion until the retainer seats against the idler.

    Note: Keep the retainer face parallel to the idler face during the tightening process.

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    Illustration 30	g02409509
    Torque retainer bolts.

18. Remove the alignment sleeve and install the remaining six bolts and tighten (Refer to Table 7 for proper retaining bolt torque specifications.)
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    Table 7

    Torque for Retaining Bolts
    Model	Dynamic Assembly Torque	Static Inspection Torque
    D11 (5/8 inch bolts)	270 ± 40 N·m (199 ± 30 lb ft)	230 N·m (170 lb ft)
    D11 (1/2 inch bolts) D10N, D9L, 589	135 ± 20 N·m (100 ± 15 lb ft)	115 N·m (85 lb ft)
    D9R, D9N, D8N, D8L, 578, D7H	85 ± 15 N·m (63 ± 11 lb ft)	70 N·m (52 lb ft)
    D6H, D5H, D4H	55 ± 10 N·m (41 ± 7 lb ft)	45 N·m (33 lb ft)

    Note: The static torque values listed in Table 7 are minimum requirements. Maximum static torque values, however, must not exceed maximum dynamic torque limits. Check the static torque specifications using a torque wrench. The retaining bolts must not move in the tightening direction when the static torque value specified in Table 7 is applied.

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    Table 8

    Spin Socket Tooling
    Model	Tooling Part Number
    D11N, D10	1U-9399
    D10N	FT-1909
    D9L	1U-9398
    D9N, D8N, D8L	FT-1910
    D7H, D6H, 973, 963	FT-1911
    D5H, D4H, 953, 943	FT-1994

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    Illustration 31	g02409510
    Spin the shaft.

19. Select the correct spin socket from Table 8 and spin the shaft 20 revolutions in both directions.
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    Table 9

    End play Tolerances
    Model	Tolerance (min/max)
    D11N, D10N, D9L, D9R, D9N, 589, D8L, D8N, 578	0.38/1.14 mm (0.015/0.045 inch)
    D7H	0.38/1.24 mm (0.015/0.050 inch)
    D7H, D6H, D5H, D4H	0.25/1.25 mm (0.010/0.049 inch)

20. Check the end play.
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    NOTICE
    If the end play does not fall within the tolerances given in Table 9, the idler must be disassembled to determine why the tolerance specification was not achieved.

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    Illustration 32	g02409513
    Install stopper.

21. Lubricate the circumference of the stopper and install stopper in the end of the shaft. The stopper must be installed 7.0 ± 15.0 mm (0.28 ± 0.59 inch) below the surface of the shaft.

    Note: For testing and filling of idlers and rollers in the track shops the preferred Caterpillar tool is the 170-5664 Test and Fill Machine

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    Illustration 33	g02722068
    (1) 8T-0831 Lubricator Tip (2) 4C-7099 Reducer Fitting (3) 170-5665 Pressure Tester (4) 5P-8998 Pipe Fitting (5) 006-0210 Pipe Tee (6) 8T-0848 Pressure Gauge (7) 4C-7090 Ball Valve

22. Pressure test the idler using FT-2724 Nitrogen Pressure Testing Tool.

    Introduce nitrogen into the lubricant cavity to a pressure of 138 kPa (20.0 psi). The cavity is to be sealed and pressure observed for 10 seconds. A pressure drop of 2.5 percent, 3.5 kPa (0.5 psi) or less is acceptable.

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    NOTICE
    Do not allow nitrogen to enter in a surge and do not use pressure in excess of 138 kPa (20.0 psi). This action may damage the seals.

    Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for proper fill volumes and oil types.

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    Illustration 34	g02409515
    Determine shaft type.

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    Illustration 35	g02409516
    Add oil to idler.

23. Add the correct quantity of oil into the idler.
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    Table 10

    Idler Oil Fill Volumes
    Model	Shaft Part Number	Shaft Type	Oil Volume
    D11R/ D11N	6T-8660	Extruded	3000 ± 25 ml
    	153-9461
    	138-4331	Double upset	1800 ± 25 ml
    D10R/ D10N	7T-0955	Extruded	1300 ± 25 ml
    	128-9693	Double upset	950 ± 25 ml
    D10L	7G-2622	Extruded	2750 ± 25 ml
    	138-4330	Double upset	1650 ± 25 ml
    D9R/ D9N	7T-2778	Extruded	1300 ± 25 ml
    	138-9378	Double upset	800 ± 25 ml
    D9L	3T-3617	Extruded	1500 ± 30 ml
    	140-0291	Double upset	775 ± 25 ml
    D8R/ D8N/ D8L	8P-6938	Extruded	1050 ± 25 ml
    	138-9712	Double upset	700 ± 25 ml

    Note: Refer to Table 10 for inverted idler oil fill volumes.

    Note: Oil fill volumes depend on the shaft configuration. Refer to Illustration 34 to determine shaft type and refer to Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for proper oil type and fill volume.

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    Table 11

    Plug Depth Specifications
    Model Usage	Plug Height above Stopper Surface
    D11N, D11R, D10, D10N, D10R, D9L, D9N, D9R, D8L, D8N, D8R, D7H, 973, 973 Steel Mill, D6H, D6R, D5H, D4H, 963, 963B, 953, 943, 939	0.0 ± 5.0 mm (0.00 ± 0.20 inch)

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    Illustration 36	g02409517
    Insert plug into stopper.

24. Use the 5P-7419 Installer Tool to insert the plug into the stopper to the proper depth. (Refer to Table 11 for proper plug depth specifications.)

    Note: The plug must not be recessed below the stopper surface after assembly.

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    Illustration 37	g02409520
    Tap end of idler shaft to determine if oil is present.

25. Tap the end of the idler shaft to determine if oil is present in the idler. If there is a dull thud, the idler contains oil. If there is a ringing noise, the idler is empty and needs filled.