Snap Ring Roller Disassembly and Assembly Procedures {0729, 4150, 4180, 4181} Caterpillar

Pipelayer

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

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

572R Series II (S/N: DSC1-UP)

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

Track-Type Loader

939 (S/N: 9GL1-UP)

939C (S/N: 6DS1-UP)

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

943B (S/N: 8WF1-UP)

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

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

953C (S/N: 2ZN1-UP; BBX1-UP)

963 (S/N: 43Y1-UP; 21Z1-UP)

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

963C (S/N: BBD1-UP; 2DS1-UP)

973 (S/N: 66G1-UP; 86G1-UP; 90L1-UP; 91L1-UP; 26Z1-UP; 32Z1-UP)

973C (S/N: LDX1-UP; 3RZ1-UP)

973D (S/N: LCP1-UP)

Track-Type Skidder

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

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

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

D5C (S/N: 6PJ1-UP; 3MK1-UP)

D5C Series III (S/N: 6ZL1-UP; 7YL1-UP; 9DL1-UP; 4WS1-UP; 5HS1-UP; 6CS1-UP; 7PS1-UP; 8ZS1-UP; 9AS1-UP)

D5G (S/N: WGB1-UP; RKG1-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)

D5K (S/N: JLF1-UP; WWW1-UP; YYY1-UP)

D5K2 (S/N: KW21-UP; KY21-UP; WT31-UP; YT31-UP; RRE1-UP; TRF1-UP; KWW1-UP; KYY1-UP)

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

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

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

D6G Series 2 (S/N: C6X1-UP)

D6H (S/N: 4RC1-UP; 3ZF1-UP; 5HF1-UP; 6CF1-UP; 3YG1-UP; 7ZK1-UP)

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

D6K2 (S/N: DFR1-UP; 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; CCS1-UP; GHS1-UP; MLW1-UP; ALY1-UP; DJY1-UP)

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

D6R Series III (S/N: WCB1-UP; TBC1-UP; WRG1-UP)

D6T (S/N: JHB1-UP; KSB1-UP; ZEB1-UP; ZJB1-UP; JZC1-UP; SMC1-UP; DTD1-UP; JWD1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; SNK1-UP; KJL1-UP; SKL1-UP; TSM1-UP; WLM1-UP; PLR1-UP; GCT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; PEZ1-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; BRP1-UP; DJR1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-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)

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 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 is given to provide disassembly and assembly procedures for Snap Ring Rollers. The information in this bulletin should serve as an aid in determining whether a snap ring roller can be reconditioned. During rebuild procedures, always correct any conditions which may have caused the original failure or wear. Never install a component that falls within the (Do not use again) criteria.

References

Safety

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.

Illustration 1	g02139237

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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 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.

Tooling and Equipment

Disassembly

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Illustration 2	g02410377
Remove the plug.

1. Drill out the plug from the end of the shaft with a 12.7 mm (0.50 inch) drill bit to drain the oil.

   Note: For removal of the retainer ring compress the shaft and the opposing end collar simultaneously. This force will unlock the retaining rings and the shaft, allowing the retainer rings to be removed properly.

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   Illustration 3	g02410442
   Applying force the shaft reference Illustration 3.

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   Illustration 4	g02410456
   Applying force to the opposing end collar reference Illustration 4.

2. Applying force to the shaft and the opposing end collar will allow the removal of the retaining rings refer to Illustrations 3 and 4.
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   Illustration 5	g02410478
   Remove end collar.

3. Remove both end collars from the shaft.
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   Illustration 6	g02410498

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   Illustration 7	g02410516
   Remove the Duo-Cone seals.

4. Remove the seals from the end collars and roller shell. Inspect the Duo-Cone seals for reuse criteria if the seals are to be reused.

   Note: Refer to Special Instruction, SEBF8511, "Reusability and Assembly Recommendations for Duo-Cone Seals" for proper Duo-Cone seal reuse information.

5. Use a feeler gauge to check the clearance between the shaft and the bearing. Refer to Table 4 for the clearance between the shaft and the bearing. If the measurements do not fall within the tolerance's given in Table 4, the bearing cannot be reused.
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   Table 4

   Sales Model	Track Roller	SHAFT / BEARING CLEARANCE Maximum / Minimum
   D3K2 D4K2 D4H D5C D5K D5K2 D5M D5N D6K2 561M 561N 939 939C 943	357-5368 SF 124-8240 DF 124-8237 SF 124-8243 DF TALL 365-0751 DF 365-075s SF	0.69 mm (0.027 inch) / 0.58 mm (0.023 inch)
   	301-0650 DF 301-0652 SF 301-0654SF	0.46 mm (0.018 inch) / 0.25 mm (0.010 inch)
   D5R2 D6N	416-7050 DF 417-3770 SF 310-4912 SF 310-4918 DF 310-4915 DF	0.71 mm (0.028 inch) / 0.55 mm (0.022 inch)
   D5H D6N D6M 953 953B 953C	121-0827 DF 121-0824 SF 121-0830 DF TALL	0.71 mm (0.028 inch) / 0.55 mm (0.022 inch)
   D6H D6R D6T 963 963B 963C	231-3088 DF 231-3087 SF 231-3089 DF TALL	0.83 mm (0.033inch) / 0.67 mm (0.026 inch)
   D7H D7R 527R 973	231-3091 DF 231-3090 SF 231-3092 DF TALL	0.84 mm (0.033 inch) / 0.68 mm (0.027 inch)
   D5H	129-2978 DF 129-2977 SF 136-9349DF TALL	0.71 mm (0.028 inch) / 0.55 mm (0.022 inch)
   PL72	471-8572 DF	0.84 mm (0.033 inch) / 0.68 mm (0.027 inch)
   527	243-5325 DF 231-3093 SF 138-1723 SF	0.83 mm (0.033inch) / 0.67 mm (0.026 inch)
   517	149-1051 DF 149-1050 DF	0.71 mm (0.028 inch) / 0.55 mm (0.022 inch)
   307E2 308E2	6I-6524 SF	0.71 mm (0.028 inch) / 0.55 mm (0.022 inch)

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   Illustration 8	g02410536
   Remove inner snap ring.

6. Remove the snap rings from both ends of the roller using the 5P-4758 Snap Ring Pliers.

   Note: During removal of the snap rings, if difficulty is encountered compress the shaft and the opposite side of the roller shell. This applied force will unload the bushing from the snap ring contributing to the removal of the snap ring.

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   Illustration 9	g02410541
   Cut away view of bushing being pressed.

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   Illustration 10	g02410557
   Press on shaft to remove the bushing.

7. Press on the shaft to remove the bushing.
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   Illustration 11	g02410676
   Remove other bushing.

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   Illustration 12	g02410698
   Remove bushing and shaft from roller.

8. Rotate the roller end for end and remove the other bushing and the shaft.

Assembly

1. Clean and inspect all roller components that are to be reused before assembly. Cleaning the roller components removes any foreign material and contaminated oil. Inspection of the track components is easier when the components are clean.
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   Illustration 13	g02410740
   Replace bushing o-ring.

2. Replace the bushing O-ring seals and lubricate the seals with the 369-9450 O-ring Compound.
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   Illustration 14	g02410756
   Position tooling and bushing into place.

3. Position the bushing in place and use the specified Roller Assembly Tool refer to Table 3.
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   Illustration 15	g02410756
   Position tooling and bushing into place.

4. Press the bushing into place.
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   Illustration 16	g02410762
   Place other bushing on shaft.

5. Position the other bushing onto the shaft.
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   Illustration 17	g02410767
   Insert the shaft and bushing.

6. Rotate the roller end for end and place the shaft with the bushing in place into the roller.
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   Illustration 18	g02410776
   Press in other bushing.

7. Press the shaft and bushing in using the proper roller assembly tool refer to Table 3.

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Illustration 19	g02410796
Compress the snap rings.

1. Compress the large snap rings using the 5P-4578 Snap Ring Pliers.
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   Illustration 20	g02410816
   Install snap ring.

2. Install the snap rings into each end of the roller.
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   Illustration 21	g02410837
   Replace o-rings on shaft.

3. Replace the rubber o-rings on the shaft.
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   Illustration 22	g02410857
   Clean seal ramp area.

4. With isopropyl alcohol, properly clean the seal ramp area on the roller and end collar. The seal ramp area is where the rubber toric ring of the Duo-Cone seal will set.
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   Table 5

   SEAL INSTALLER TOOLING
   Sales Model	Track Roller	Seal Installer Part No.
   D3K2 D4K2 D4H D5C D5K D5K2 D5M D5N D6K2 561M 561N 939 939C 943	357-5368 SF 124-8240 DF 124-8237 SF 124-8243 DF TALL 301-0650 DF 301-0652 SF 301-0654SF 365-0752 SF 365-0751 DF	224-9466 123-3801
   D5R2 D6N	416-7050 DF 417-3770 SF 310-4912 SF 310-4918 DF 310-4915 DF	224-9466 123-3801
   D5H D6N D6M 953 953B 953C	121-0827 DF 121-0824 SF 121-0830 DF TALL	224-9466 123-3801
   D6H D6R D6T 963 963B 963C	231-3088 DF 231-3087 SF 231-3089 DF TALL	224-9467 136-6813
   D7H D7R 527R 973	231-3091 DF 231-3090 SF 231-3092 DF TALL	224-9467 136-6813
   D5H	129-2978 DF 129-2977 SF 136-9349DF TALL	224-9466 123-3801
   PL72	471-8572 DF	224-9467 136-6813
   527	243-5325 DF 231-3093 SF 138-1723 SF	224-9467 136-6813
   517	149-1051 DF 149-1050 DF	224-9466 123-3801
   307E2 308E2	6I-6524 SF	123-2999

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   NOTICE
   There can be no oil residue on the Duo- Cone seal contact area of the bushing. Do not use oil-based preservatives on the bushing.

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   Illustration 23	g02410860
   Lubricate the toric ring.

5. Apply isopropyl alcohol to the rubber toric rings. This isopropyl alcohol will help lubricate the rubber toric ring during the installation of the Duo-Cone seal. The isopropyl alcohol will evaporate leaving no residue behind.
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   Illustration 24	g02410863
   Install the Duo-Cone seals into the bushings using even perpendicular force.

6. Use the proper Duo-Cone seal installer refer to Table 5. Make sure to use an even, perpendicular force to install the seal. This force will prevent twisting of the toric ring.
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   Illustration 25	g02410869
   Install seals into end collars.

7. Use the proper Duo-Cone seal installer and isopropyl alcohol to install the seals into the end collars.
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   Illustration 26	g02410876
   Check seal height.

8. Check the assembled seal height at four locations 90 degrees apart. The difference in height around the ring must not exceed 1.0 mm (0.04 inch).

9. Make sure that the seal faces are free of all debris. Apply a thin film of clean oil to the entire seal ring face of each seal. Use a lint free applicator or horse hair brush to distribute the oil evenly.
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   NOTICE
   Do not get oil on the rubber toric rings. Oil on the rubber toric rings will lead to a failure.

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   Illustration 27	g02410878
   Install the end collars.

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   Illustration 28	g02410897
   Install the end collars.

10. Install the end collars.
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    Illustration 29	g02410917
    Replace the retaining ring.

11. Compress the roller and replace the retaining ring in the end collar.
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    Illustration 30	g02410937
    Insert stopper.

12. Insert the properly sized stopper in the shaft using the 5P-7392 Stopper Installation Group. Lubricate the circumference of the stopper with a lightweight oil.

13. Prior to test, rotate end collars and/or shaft a minimum of 20 revolutions in both directions.
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    Table 6

    Stopper Part Numbers
    Sales Model	Track Roller	Stopper Part No.
    D3K2 D4K2 D4H D5C D5K D5K2 D5M D5N D6K2 561M 561N 939 939C 943	357-5368 SF 124-8240 DF 124-8237 SF 124-8243 DF TALL 301-0650 DF 301-0652 SF 301-0654SF 365-0752 SF 365-0751 DF	7G-4332
    D5R2 D6N	416-7050 DF 417-3770 SF 310-4912 SF 310-4918 DF 310-4915 DF	7G-4332
    D5H D6N D6M 953 953B 953C	121-0827 DF 121-0824 SF 121-0830 DF TALL	7G-4332
    D6H D6R D6T 963 963B 963C	231-3088 DF 231-3087 SF 231-3089 DF TALL	7G-4332
    D7H D7R 527R 973	231-3091 DF 231-3090 SF 231-3092 DF TALL	7G-4332
    PL72	471-8572 DF	7G-4332
    973 Steel Mill	-	3T-3800 High Temp.
    D5H	129-2978 DF 129-2977 SF 136-9349DF TALL	7G-4332
    527	243-5325 DF 231-3093 SF 138-1723 SF	7G-4332
    517	149-1051 DF 149-1050 DF	7G-4332
    307E2 308E2	6I-6524 SF	7G-4332

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    Illustration 31	g02410976
    Add oil to the roller.

14. Use the 170-5664 Test and Fill Cart Gp to evaluate and fill the roller, refer to Illustration 31 above.

15. If the Test and Fill Cart Gp is not available. Reference Special Instruction, SEBF8594, "Nitrogen Pressure Test Unit"perform the following test using the FT-2724 Pressure Gauge Tool Gp, refer to Illustration 32.
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    Illustration 32	g02410956

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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

    Note: Add the correct quantity of oil into the roller. Refer to Special Instruction, SEBF8574, "Oil Fill Volume for Track Rollers" for proper fill volumes and oil types.

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    NOTICE
    Do not allow nitrogen to enter in a surge and do not use pressure in excess of 138.0 kPa (20.02 psi). Excessive pressure or a surge of pressure may damage the seals.

16. Check end play of the roller. The end play must fall within the tolerance given in Table 7.
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    Table 7

    ENDPLAY TOLERANCE
    Sales Model	Track Roller	ENDPLAY TOLERANCE Maximum / Minimum
    D3K2 D4K2 D4H D5C D5K D5K2 D5M D5N D6K2 561M 561N 939 939C 943	357-5368 SF 124-8240 DF 124-8237 SF 124-8243 DF TALL 301-0650 DF 301-0652 SF 301-0654SF 365-0752 SF 365-0751 DF	1.23 mm (0.048 inch) / 0.25 mm (0.010 inch)
    D5R2 D6N	416-7050 DF 417-3770 SF 310-4912 SF 310-4918 DF 310-4915 DF	1.23 mm (0.048 inch) / 0.15 mm (0.006 inch)
    D5H D6N D6M 953 953B 953C	121-0827 DF 121-0824 SF 121-0830 DF TALL	1.29 mm (0.051 inch) / 0.21 mm (0.008 inch)
    D6H D6R D6T 963 963B 963C	231-3088 DF 231-3087 SF 231-3089 DF TALL	1.33 mm (0.052 inch) / 0.25 mm (0.010 inch)
    D7H D7R 527R 973	231-3091 DF 231-3090 SF 231-3092 DF TALL	1.24 mm (0.049 inch) / 0.26 mm (0.010 inch)
    D5H	129-2978 DF 129-2977 SF 136-9349DF TALL	1.29 mm (0.051 inch) / 0.21 mm (0.008 inch)
    PL72	471-8572 DF	1.27 mm (0.050 inch) / 0.19 mm (0.007 inch)
    527	243-5325 DF 231-3093 SF 138-1723 SF	1.33 mm (0.052 inch) / 0.25 mm (0.010 inch)
    517	149-1051 DF 149-1050 DF	1.29 mm (0.051 inch) / 0.21 mm (0.008 inch)
    307E2 308E2	6I-6524 SF	1.29 mm (0.051 inch) / 0.21 mm (0.008 inch)

    Note: If the end play does not fall within the given tolerances, disassemble the roller to determine the cause.

17. Select the correct plug from Table 8 to be installed into the stopper from Table 6.
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    Table 8

    PLUG PART NUMBERS
    Sales Model	Track Roller	Plug Part No.
    D3K2 D4K2 D4H D5C D5K D5K2 D5M D5N 561M D6K2 561N 939 939C 943	357-5368 SF 124-8240 DF 124-8237 SF 124-8243 DF TALL 301-0650 DF 301-0652 SF 301-0654SF 365-0752 SF 365-0751 DF	6Y-0473
    D5R2 D6N	416-7050 DF 417-3770 SF 310-4912 SF 310-4918 DF 310-4915 DF	6Y-0473
    D5H D6N D6M 953 953B 953C	121-0827 DF 121-0824 SF 121-0830 DF TALL	6Y-0473
    D6H D6R D6T 963 963B 963C	231-3088 DF 231-3087 SF 231-3089 DF TALL	6Y-0473
    D7H D7R 527R 973	231-3091 DF 231-3090 SF 231-3092 DF TALL	6Y-0473
    PL72	471-8572 DF	6Y-0473
    973 Steel Mill	-	3T-3799 High Temp.
    D5H	129-2978 DF 129-2977 SF 136-9349DF TALL	6Y-0473
    527	243-5325 DF 231-3093 SF 138-1723 SF	6Y-0473
    517	149-1051 DF 149-1050 DF	6Y-0473
    307E2 308E2	6I-6524 SF	6Y-0473

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    Illustration 34	g02410981
    Ready the plug for installation.

18. Insert the plug into the 5P-7419 installation tool and lightly lubricate the plug.
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    Illustration 35	g02410998
    Install the plug.

19. Use the 5P-7419 installation tool to install the plug to the proper depth.
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    Illustration 36	g02411016
    Tap the roller rim to see if the roller contains oil.

20. Tap the roller rim with a hammer to determine if the roller is full. A ringing noise will verify that the roller is empty. A dull thud will verify that the roller has oil.