Oval Track Roller Disassembly and Assembly Procedures {4180} Caterpillar

Excavator

215 (S/N: 96L1-UP; 57Y1-UP; 14Z1-UP; 61Z1-UP; 95Z1-UP)

215B (S/N: 9YB1-UP; 2XC1-UP; 4FC1-UP; 4JC1-UP)

215C (S/N: 4HG1-UP)

215D (S/N: 9TF1-UP)

219 (S/N: 5CF1-UP)

219D (S/N: 5XG1-UP)

225 (S/N: 20S1-UP; 51U1-UP; 76U1-UP; 61X1-UP)

225B (S/N: 2ZD1-UP; 3YD1-UP)

225D (S/N: 6RG1-UP; 2SJ1-UP)

235 (S/N: 32K1-UP; 64R1-UP; 62X1-UP; 81X1-UP; 83X1-UP)

235B (S/N: 7WC1-UP; 9PC1-UP; 1FD1-UP; 4ED1-UP)

235C (S/N: 5AF1-UP; 2PG1-UP; 3WG1-UP; 4DG1-UP)

235D (S/N: 8KJ1-UP; 8TJ1-UP)

245 (S/N: 94L1-UP; 95V1-UP; 82X1-UP; 84X1-UP)

245B (S/N: 6MF1-UP; 1SJ1-UP)

245D (S/N: 7ZJ1-UP; 4LK1-UP)

5110B (S/N: AAA1-UP)

Pipelayer

561B (S/N: 92J1-UP)

561C (S/N: 92J1-UP)

572F (S/N: 96N1-UP)

572G (S/N: 8PC1-UP; 40U1-UP)

572R (S/N: AAC1-UP; 2HZ1-UP)

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

583H (S/N: 38A1-UP; 78V1-UP)

583K (S/N: 78V1-UP)

594 (S/N: 62H1-UP; 96V1-UP)

594H (S/N: 96V1-UP)

Track-Type Loader

931 (S/N: 08N1-UP; 10N1-UP)

941 (S/N: 70H1-UP; 80H1-UP; 16U1-UP)

941B (S/N: 70H1-UP; 80H1-UP)

943 (S/N: 03Y1-UP; 31Y1-UP; 63Y1-UP; 73Y1-UP; 04Z1-UP; 19Z1-UP)

951 (S/N: 58D1-UP; 69H1-UP; 79H1-UP; 86J1-UP)

951B (S/N: 32F1-UP; 69H1-UP; 79H1-UP; 86J1-UP)

951C (S/N: 69H1-UP; 86J1-UP)

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

955 (S/N: 58D1-UP; 61H1-UP; 65H1-UP; 87H1-UP; 64J1-UP)

955A (S/N: 42D1-UP)

955K (S/N: 61H1-UP; 71J1-UP; 85J1-UP; 57M1-UP)

955L (S/N: 64J1-UP; 85J1-UP; 13X1-UP; 08Y1-UP)

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

963K (S/N: LBL1-UP)

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

973D (S/N: LCP1-UP)

977 (S/N: 57D1-UP; 84G1-UP; 46H1-UP; 77H1-UP; 29K1-UP)

977K (S/N: 46H1-UP; 48J1-UP; 11K1-UP)

977L (S/N: 48J1-UP; 11K1-UP; 14X1-UP; 64X1-UP; 95X1-UP)

983 (S/N: 38K1-UP)

983B (S/N: 58X1-UP)

Track-Type Tractor

5 (S/N: 57D1-UP; 84G1-UP)

6 (S/N: 57D1-UP; 62S1-UP)

D3 (S/N: 06N1-UP; 79U1-UP)

D4 (S/N: 22C1-UP; 44H1-UP; 20J1-UP; 59J1-UP; 60J1-UP; 61J1-UP; 82J1-UP; 83J1-UP; 84J1-UP; 07R1-UP)

D4D (S/N: 22C1-UP; 97F1-UP; 44H1-UP; 47H1-UP; 20J1-UP; 59J1-UP; 60J1-UP; 61J1-UP; 65J1-UP; 66J1-UP; 82J1-UP; 83J1-UP; 84J1-UP; 07R1-UP; 74U1-UP)

D5 (S/N: 62J1-UP; 63J1-UP; 67J1-UP; 93J1-UP; 94J1-UP; 95J1-UP; 96J1-UP; 98J1-UP; 06R1-UP; 12R1-UP)

D5B (S/N: 8MB1-UP; 5LD1-UP; 8HD1-UP; 22X1-UP; 23X1-UP; 24X1-UP; 25X1-UP; 26X1-UP; 43X1-UP; 44X1-UP; 45X1-UP; 46X1-UP; 47X1-UP; 48X1-UP; 49X1-UP; 21Y1-UP)

D6 (S/N: 19B1-UP; 46J1-UP; 47J1-UP; 99J1-UP; 10K1-UP)

D6C (S/N: 90B1-UP; 46J1-UP; 47J1-UP; 69J1-UP; 99J1-UP; 10K1-UP; 26K1-UP; 17R1-UP; 23U1-UP; 24U1-UP; 69U1-UP; 49W1-UP)

D6D (S/N: 5YB1-UP; 19B1-UP; 6HC1-UP; 36C1-UP; 37C1-UP; 38C1-UP; 7YK1-UP; 9FK1-UP; 74W1-UP; 75W1-UP; 03X1-UP; 04X1-UP; 05X1-UP; 06X1-UP; 19X1-UP; 20X1-UP; 30X1-UP; 31X1-UP; 32X1-UP; 33X1-UP; 01Y1-UP)

D6G Series 2 (S/N: 2MJ1-UP)

D7E (S/N: TJA1-UP; MDB1-UP; SCG1-UP; TAN1-UP)

D7F (S/N: 92E1-UP; 61G1-UP; 93N1-UP; 94N1-UP)

D7G Series 2 (S/N: 7MB1-UP; 3ZD1-UP; 3GF1-UP; 35N1-UP; 64V1-UP; 65V1-UP; 91V1-UP; 92V1-UP; 44W1-UP; 45W1-UP; 72W1-UP)

D8 (S/N: 76V1-UP; 77V1-UP)

D8H (S/N: 36A1-UP; 46A1-UP)

D8K (S/N: 66V1-UP; 76V1-UP; 77V1-UP)

D9 (S/N: 66A1-UP; 91J1-UP; 90V1-UP)

D9G (S/N: 66A1-UP; 90J1-UP; 91J1-UP)

D9H (S/N: 12U1-UP; 90V1-UP; 97V1-UP; 98V1-UP; 99V1-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 oval track rollers. The information in this bulletin should serve as an aid in determining whether an oval track roller 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

Refer to Special Instruction, SEBF8511, "Reusability Recommendations for Duo-Cone Seals"Special Instruction, SEBF8574, "Track Roller Oil Fill Volume"Special Instruction, SEHS8364, "Assembly and Installation of Conventional Duo-Cone Seals"Special Instruction, SEHS8484, "Tool and Specification Chart for Conventional Duo-Cone Seals"

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. Hazardous steps will be identified by warning symbols like the ones below.

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.

Disassembly

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Illustration 2	g02415256
Remove plug and stopper.

1. Remove the plug and stopper to drain the oil.
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   Illustration 3	g02415277
   Remove the retaining ring.

2. Compress the roller using a press or similar tooling. Use needle nose pliers to remove the retaining rings from the end collars.
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   Illustration 4	g02415279
   Remove the end collars.

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

3. Remove the end collars by holding end collars in place and pressing only on the shaft.
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   Illustration 5	g02415325
   Remove the duo-cone seals.

4. After inspecting the seals for reuse criteria, remove the seals from the end collars and roller shell.

5. Use a feeler gauge to check the clearance between the shaft and the bearing. Reference Table 2 to check the shaft and bearing clearance.
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   Table 2

   Shaft / Bearing Clearance
   Model Usage	Clearance mm (in)
   983B, 983, 245	0.203 mm (0.0080 inch) 0.148 mm (0.0060 inch)
   D9H, D9G, 594H, 594	0.470 mm (0.0185 inch) 0.356 mm (0.0140 inch)
   D8K, D8H, D7G, D7E, D7F, D6G, D6E, D6D, D6C, D5B, D5, D4D, D3, 977L, 977K, 977, 973D, 973, 963K, 963, 955, 955L, 955K, 953, 951C, 951B, 951, 943, 941B, 941, 931, 583K, 583H, 572, 572F, 572G, 561C, 235, 227, 225, 219, 215B, 215	0.362 mm (0.0143 inch) 0.275 mm (0.0108 inch)

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   Illustration 6	g02415286
   Remove the bolts.

6. Remove the bolts from both ends of the roller.
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   Illustration 7	g02415356
   Press the shaft to remove the bushing.

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   Illustration 8	g02415340
   Cut away view of bushing being pressed.

7. Press the shaft to remove the bushing.
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   Illustration 9	g02415364
   Remove the other bushing.

8. Rotate the roller end-for-end and remove the other bushing and the shaft.
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   Illustration 10	g02415369
   Remove the shaft o-rings.

9. Remove the shaft o-rings.

Assembly

1. Wash and remove all debris from the track roller and all the track rollers components.

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

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   Illustration 11	g02415376
   Lubricate and replace the bushings o-rings.

2. Replace the bushing o-ring seals and lubricate the seals with 369-9450 Petro Gel Grease.

   Note: Always use new rubber components.

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   Illustration 12	g02415380
   FT-0578 Bushing Alignment Tool.

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   Illustration 13	g02415382
   Press the bushing into place.

3. Align the bolt holes and press one bushing using the FT-0578 Bushing Alignment Tool.

4. Press the other bushing and the shaft into the roller assembly.
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   Illustration 14	g02415386
   Torque the bushing bolts.

5. Install remaining bolts into both bushings and torque to specifications given in table 3.
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   Table 3

   Torque for Retaining Bolts
   Model Usage	Dynamic Torque N*M (lb-ft)	Static Torque N*M (lb-ft)
   983B, 983, 245	135 ± 20 N·m (99.6 ± 14.8 lb ft)	115 N·m (84.8 lb ft)
   D7G, D7F, D7E, D6G, D6E, D6D, D6C, D5B, D5, D4D, D3, 977K, 977L, 977, 973D, 973, 963K, 963, 961, 955L, 955K, 955, 953, 561C, 951B, 951, 943, 941B, 941, 931, 572, 572F, 572G, 961C, 235, 227, 225, 219, 215B, 215	50 ± 10 N·m (36.90 ± 7.4 lb ft)	40 N·m (29.5 lb ft)
   D9H, D9G, D8K, D8H, 594H, 594, 583K, 583H	105 ± 20 N·m (77.4 ± 14.8 lb ft)	85 N·m (62.7 lb ft)

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   Illustration 15	g02415481
   Replace the o-rings on the shaft.

6. Replace the roller shaft o-rings using 369-9450Petro Gel Grease.

7. Clean the seal ramps with alcohol or other approved cleaner. Make sure that there is no oil, debris, or other contaminants on the contacting surfaces of the Duo-Cone seals and the bushing.

   Note: When lubricating the toric rings, alcohol with a purity of 99% or greater must be used. Using 99% pure alcohol will allow for proper drying of the Duo-Cone seals and will prevent slipping of the toric rings.

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   Illustration 16	g02415483
   Lubricate the toric ring.

8. Apply alcohol to the rubber toric rings. Alcohol will ease the installation of the Duo-Cone seals. Refer to Special Instruction, SEHS8364, "Assembly and Installation of Conventional Duo-Cone Seals".
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   Illustration 17	g02415484
   Install the duo-cone seals into the bushings using an even, perpendicular force.

9. Use the proper Duo-Cone seal installer from Table 4 to install the seals into the bushings. Make sure to use an even, perpendicular force to install the seal. Even force will prevent twisting of the toric ring.

   Note: The toric ring must not be twisted on the seal ring.

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   Illustration 18	g02415485
   Install the duo-cone seals into the end collars.

10. Use the proper duo-cone seal installer from Table 4 to install the seals into the end collars.
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    Table 4

    Seal Installer Tool
    Model Usage	Installer Part Number
    D6D, D6C, D5B, D5, D4D, D3, 963K, 963, 961, 955L, 955K, 955, 953, 951C, 951B, 951, 943, 941B, 941, 931, 572, 572F, 572G, 561C, 235, 225, 227, 219, 215B, 215	1U-8843
    D9H, D9G, 594H, 594	1U-8842
    D8K, D8H, 583K, 583H	1U-8841
    D7G, D7F, D7E, D6G, D6E, 983B, 983, 977L, 977K, 977, 973D, 973, 245,	1U-8840

11. Dry the Duo-Cone seals using pressurized air at 30 psi for 1 minute.
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    Illustration 19	g02415486
    Check the seal height.

12. Check the assembly seal height in four locations 90 degrees apart. The difference in height around the seal must not exceed 1 mm (0.04 inch).
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    Illustration 20	g02415488

13. Make sure that the seal faces are free of all debris. Apply a thin film of clean oil to the seal face of the Duo-Cone seal within the end collar. Use the same oil as used in the roller. If more convenient, apply a thin film of clean oil to the seal face Duo-Cone seal with in the roller assembly. Do not use a horse hair brush to distribute the oil.

    Note: Do not get oil on the rubber toric ring. Oil will lead to slipping between the toric ring and seal ramp.

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    Illustration 21	g02415490
    Install the end collars.

14. Install the end collars.
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    Illustration 22	g02415491
    Replace the retaining ring.

15. Compress the end collars using a press or similar tooling and replace the retaining ring.

16. Insert the properly sized stopper into the shaft using the 5P-7392 Stopper Installation Group. Oil the stopper with a light oil.
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    Illustration 23	g02415492
    Use the Test and fill machine 170-5664 to evaluate and fill the roller.

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    Illustration 24	g02415496
    Pressure test the roller using FT2724.

17. Use the Test and Fill Machine 170-5664 to evaluate and fill the roller. If the Test and Fill Machine 170-5664 is not available, perform the following test using the FT-2724. Introduce nitrogen into the lubricant cavity to a pressure of 138 kPa (20 psi). Turn the ball valve to a shut-off position. Next close the pressure gauge. The pressure is to be observed for 10 seconds. A pressure drop of 2.5 percent or less is acceptable.

    Note: If using FT-2724, do not allow air to enter in a surge and do not use pressure more than 138 kPa (20 psi) as excessive pressure will damage the seals.

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    Illustration 25	g02415498
    Add oil to the roller.

18. Add the correct quantity of oil to the roller. Refer to Track Roller Oil Fill Volume, SEBF8574.

19. Check the end-play of the roller. The end-play must fall within the tolerance given in Table 5.
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    Table 5

    End-play Tolerances
    Model Usage	End-play End-play mm (in)
    D8K, D8H, D7G, D7F, D7E, D6G, D6E, D6D, D6C, D5B, D5, D4D, D3, 983B, 983, 977L, 977K, 977, 973D, 973, 963K, 963, 955,955L, 955K, 953, 951C, 951B, 951, 943, 941B, 941, 931, 583K, 583H, 572, 572F, 572G, 561C, 245, 235, 227, 225, 219, 215B, 215	0.26 mm (0.010 inch) 0.92 mm (0.036 inch)
    D9H, D9G, 594H, 594	0.35 mm (0.014 inch) 0.93 mm (0.037 inch)

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

20. Insert the plug into the 5P-7419 Plug Installation Tool and lightly lubricate the plug.

21. Use the 5P-7419 Plug Installation Tool to install the plug to the proper depth.
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    Illustration 26	g02415499
    Tap the roller to see if the roller is filled with oil inside.

22. Tap the end of the roller to determine if the roller is full of oil. If there is a ringing noise, the roller is empty. If there is a dull thud, the roller has oil.