- Pipelayer
- 578 (S/N: 8HB1-UP)
- 583R (S/N: 2XS1-UP)
- 589 (S/N: 31Z1-UP)
- 583R (S/N: 2XS1-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; 90L1-UP; 91L1-UP; 26Z1-UP; 32Z1-UP)
- 943 (S/N: 31Y1-UP; 63Y1-UP; 73Y1-UP; 04Z1-UP; 19Z1-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: 8PB1-UP; 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; 1RW1-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; 7TL1-UP; 8BL1-UP; WDM1-UP)
- D10N (S/N: 3SK1-UP)
Introduction
Revision | Summary of Changes in SEBF8581 |
04–06 | Added serial number prefixes for New Product Introduction. |
03 | Updated Introduction and Safety |
© 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:
- Caterpillar Dealer Technical Communicator
- Dealer Solution Network
- Caterpillar Technical Representative
- Knowledge Network
Summary
The following information is given to provide disassembly and assembly procedures for track rollers with inverted Duo-Cone seals.
The information in this bulletin should serve as an aid in determining whether a track roller 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
Media | Title |
SEBF8511 | "Reusability Recommendations for Duo-ConeSeals" |
SEHS8515 | "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers" |
SEBF8574 | "Track Roller Oil Fill Volume" |
SEHS8483 | "Assembly and Installation of Inverted Duo-Cone Seals" |
SEHS8974 | "Tool and Specification Chart for Inverted Duo-Cone Seals" |
SEBF8597 | "Reconditioning Procedure for Seal Ramps on Inverted Style Idler and Roller Shafts" |
SEBF8596 | "Guideline for Roller and Idler Component Reuse" |
SEBF8608 | "Torque Audit Procedure for Roller and Idler Retainer Bolts" |
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. 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.
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. |
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. |
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
Required Tools | |
Seal Installer | |
Model Number | Part Number |
D11N, D11R | |
D10, D10N, D10R, D9L, 589, 583R | |
D9N, D9R | |
D8L, D8N, D8R, 578 | |
D7H, D6H, D6R, 973, 973 Steel Mill | |
963, 963B | |
D5H, D4H, 953, 953B, 943, 943B, 939 | |
Seal Height Tooling | |
All Models | |
Miscellaneous Tooling | |
Part Description | Part Number |
Plug Installation Tool | |
Stopper Installation Tool Group | |
O-ring Assembly Compound |
Disassembly
- Drill out the plug from the end of the shaft with a 0.5 inch drill bit to drain the oil.
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Illustration 3 g02420077 Remove bolts and retainers. Show/hide tableIllustration 4 g02420078 Remove thrust washers. - Remove the six bolts and the retainer assembly, including the thrust washers, from each end of the track roller.
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.
Show/hide tableIllustration 5 g02420079 Remove seals from retainers. - Remove the large diameter O-ring seals from the O-ring grooves on each retainer assembly.
Note: If the Duo-Cone seals are reusable, keep the seals in matching pairs. Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals" for proper reuse information.
Show/hide tableIllustration 6 g02420080 Remove the Duo-Cone seals from the roller shaft. - Remove the Duo-Cone seals from the roller shaft and retainer assemblies.
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Illustration 7 g02420081 Remove retainer seals. - Remove the Duo-Cone seals from the roller shaft and retainer assemblies. Inspect each set of seals side by side for reusability.
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Illustration 8 g02420082 Remove toric stabilizers. - Remove the toric stabilizers from both sides of the track roller.
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Table 4 Shaft/Bearing Clearance Model Number Clearance (min to max) D11N, D11R, D10N,
D10R, D9L, D9N, D9R
589, D8L, D8N,
D8R, 578, 583R,
D7H, 973, 973 Steel Mill0.44 to 0.56 mm (0.017 to 0.022 inch) D6H, D6R, 963, 963B 0.29 to 0.41 mm (0.011 to 0.016 inch) D5H, 953, 953B 0.30 to 0.52 mm (0.012 to 0.020 inch) D4H, 943, 943B, 939 0.24 to 0.46 mm (0.009 to 0.018 inch) - Measure the shaft-to-bearing clearance using a feeler gauge. The clearance must fall within the specifications given in Table 4.
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Illustration 9 g02420083 Remove the shaft. - Partially slide the shaft out of the track roller. If necessary, attach a hoist to help remove the shaft the rest of the way.
Illustration 2 | g02420076 |
Remove plug and stopper. |
Illustration 10 | g02420084 |
Shaft with hoist attached. |
Assembly
NOTICE |
---|
It is important that the correct assembly and installation procedures are followed when using inverted Duo-Cone seals. Many failures are the direct result of mistakes made during assembly and installation of seals. |
NOTICE |
---|
It is important to maintain the surface roughness of the shaft ramp area when removing debris from the roller shaft. Failure to maintain the integrity of this surface could lead to a failure in the roller. |
Note: If the seal ramp area does not have a Ra value 5.00 to 8.75 micro meter, the seal ramp must be reconditioned. Refer to Undercarriage Reconditioning Bulletin, SEBF8597, "Reconditioning Procedure for Seal Ramps on Inverted Style Idler and Roller Shafts" for proper seal ramp reconditioning.
- Wash and remove all debris from the track roller and all of the rollers components.
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Illustration 12 g02420086 Clean components with a lint free cloth. - Use alcohol or other approved cleaning agents to clean the roller components. Dry with a lint free cloth.
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Illustration 13 g02420087 Install O-rings into retaining grooves. - Use 369-9450 O-ring Assembly Compound to install the new O-rings into the retaining grooves.
Note: Always use new rubber components.
Show/hide tableIllustration 14 g02420088 Install seals into retainers. Show/hide tableIllustration 15 g02420089 (1) Retainer - Lubricate the rubber retainer seal 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 in the retainer.
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Illustration 16 g02420090 Check retainer seal height. Show/hide tableIllustration 17 g02429416 Check retainer seal height.
(A) Retainer seal height
(1) Retainer
(2) Retainer seal - Check the assembled seal height (A) of the retainer seal (2) at four locations 90 degrees apart. (Refer to Table 3 for proper seal height tooling.) The difference in height must not exceed
0.3 mm (0.01 inch) . Also, turn the retainer (1) over to ensure that the rubber O-ring is in contact all around the bottom of the base in the retainer.Note: If seal height specification is not met, the Duo-Cone seals must be removed and reinstalled.
Show/hide tableNOTICE Use care when installing the shaft in the track roller. The shaft may scrape bronze particles from the bearing, the bronze particles will cause a failure in the rollers.
Show/hide tableIllustration 18 g02420092 Install shaft. - Install the shaft into the track roller.
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Illustration 19 g02420093 Install the toric stabilizers. Show/hide tableIllustration 20 g02420094 (3) Shaft
(4) Toric stabilizer - 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 roller. (Refer to Illustration 20.)
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Illustration 21 g02420095 Install thrust washers. - Install the thrust washers on both ends of the track roller shaft.
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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. Also verify the toric position for new Duo-Cone seals. Failure to do so may result in a failure of the roller.
Show/hide tableIllustration 22 g02420096 Assemble shaft seal.
(5) Seal ring
(6) Toric ring
(7) Retaining lip
(8) Seal ring ramp - If 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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Illustration 23 g02420097 Install Duo-Cone seals onto shaft. - Use the correct installation tool to install the Duo-Cone seal onto the roller shaft. (Refer to Table 3 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 24 g02420098 Check seal height on shaft. Show/hide tableIllustration 25 g02420099 Check seal height on shaft.
(B) Shaft seal height
(9) Shaft seal face
(10) Thrust face - Check the assembled Duo-Cone seal height (B) from seal face (9) to thrust face (10) at four locations 90 degrees apart. (Refer to Table 3 for proper seal height tooling.) The difference in height around the seal must not exceed
0.8 mm (0.03 inch) .Note: The thrust washer must be removed to check shaft seal height.
Note: If the seal height specification is not met, the Duo-Cone seals must be removed and reinstalled.
Show/hide tableIllustration 26 g02420100 Wipe shaft seal ring face with lint free cloth. - 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, it is important to minimize the time between seal ring oil application and assembly of the retainer to the roller assembly.
- Apply a thin layer of oil to the entire face of the seal rings.
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Illustration 27 g02420117 Wipe entire retainer seal face with lint free cloth. - Wipe the entire retainer seal face with a lint free cloth.
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Table 5 Alignment Sleeve Tooling Model Usage Tooling Part Number D11N, D11R, D10 8T-0824 D10N, D10R, D9L, 583R, 589 8T-0823 D9N, D9R, D8N, D8L, D7H,
D6H, D6R, 973, 578,
973 Steel Mill, 963, 963B8T-0822 D5H, D4H, 953, 953B,
943, 943B, 9398T-0945 Show/hide tableIllustration 28 g02420118 Slide on the retainer. - Slip the retainer assembly over the shaft and carefully move the alignment sleeve and the retainer to the final position. (Refer to Table 5 for correct alignment sleeve.)
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Table 6 Torque for Retaining Bolts Model Dynamic Assembly Torque Static Inspection Torque D11N, D11R
(5/8 inch bolts)270 ± 40 N·m (199 ± 30 lb ft.) 230 N·m (170 lb ft) D10N, D10R, D9L, D9N,
D9R, 583R, 589,
D8L, D8N, D8R, 578,
D7H, 973, 973 Steel Mill
(1/2 inch bolts)135 ± 20 N·m (100 ± 15 lb ft) 115 N·m (85 lb ft) D6H, D6R, 963, 963B,
D5H, 953, 953B,
D4H, 943, 943B, 939
(3/8 inch bolts)55 ± 10 N·m (41 ± 7 lb ft) 45 N·m (33 lb ft) Show/hide tableIllustration 29 g02420119 Tighten two retaining bolts opposite to each other. Show/hide tableIllustration 30 g02420120 Torque retaining bolts to proper specifications. - Once in position, evenly apply pressure to the alignment sleeve. While applying pressure, start two bolts 180 degrees from one another. In an alternating fashion tighten bolts until the retainer seats against the roller and the thrust washer is able to stay in place. Remove the alignment sleeve, install, and tighten the remaining bolts. (Refer to Table 6 for proper retaining bolt torque specifications.) Repeat steps 4 - 16 for opposite side of roller.
Note: The static inspection torque values listed in Table 6 are minimum requirements. Maximum static inspection torque values, however, must not exceed maximum dynamic assembly torque limits. Check bolt static torque specification using a torque wrench. The retaining bolt must not move in the tightening direction when the static torque value specified in Table 6 is reached.
Show/hide tableTable 7 Spin Socket Tooling Model Usage Tooling Part Number D11N, D11R, D10 1U-9398 D10N, D10R, D9L, 589, 583R FT-1910 D9N, D8L, D8N, D8R, D7H, D6H,
973, 973 Steel Mill, 963, 963B, 578FT-1911 D5H, D4H, 953, 953B,
943, 943B, 939FT-1984 Show/hide tableIllustration 31 g02420121 Spin the shaft. - Select the correct spin socket from Table 7 and spin the shaft 20 revolutions in each direction at less than 100 rpm.
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Table 8 End Play Tolerances Model Tolerance
(min to max)D11N, D11R, D10N,
D10R, D9N, D9R,
D8L, D8N, D8R,
578, 583R, D7H,
973, 973 Steel Mill0.25 to 1.25 mm (0.010 to 0.050 inch) D9L, 589, D6H,
D6R, 963, 963B,
D5H, 953, 953B,
D4H, 943, 943B, 9390.25 to 0.85 mm (0.010 to 0.033 inch) - Check the end play.
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NOTICE If the end play does not fall within the tolerances given in Table 8, disassemble the roller to determine why the tolerance specification is not met.
Show/hide tableIllustration 32 g02420122 Install stopper. - Lubricate the circumference of the stopper and install the 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.Show/hide tableIllustration 33 g02420123 Use the 170-5664 Test and Fill Cart Gp to evaluate and fill the roller.Show/hide tableIllustration 34 g02420124 Pressure test the roller using FT-2724 Pressure Gauge Tool Gp.Show/hide tableIllustration 35 g02442296 Pressure testing tool Ft2724 - Use the 170-5664 Test and Fill Cart Gp to evaluate and fill the roller. If the Test and Fill Cartis not available, perform the following test using the FT-2724 Pressure Gauge Tool Gp. Fill the joint to the required amount.
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Table 9 Track Roller Oil Fill Volumes Model Shaft Part Number Shaft Type Oil Volume (ml) D11N
D11R
D11R (Arctic)6T-9366 Extruded 2100 ± 50 146-3583 Double upset 1650 ± 50 D10L
D10L (Arctic)8E-6653 Double upset 850 ± 30 D10N
D10R7T-0688 Extruded 1600 ± 30 146-3584 Double upset 1200 ± 30 D10R (Military) 7T-0688 Double upset 1600 ± 30 D9L, 589
D9L (Arctic)8E-6661 Double upset 650 ± 30 D9N, D9R 7T-1265 Extruded 905 ± 15 8E-6643 Double upset 850 ± 30 D8L, D8R, D8N
579, 5786T-7500 Double upset 500 ± 15 D7H
973 (Steel Mill)3T-7392 Double upset 450 ± 15 D6H, 963 6T-0720 Double upset 400 ± 15 D5H, 953 3T-9875 Double upset 300 ± 15 D4H, 943, 939 8E-6573 Double upset 270 ± 15 583R 138-9712 Double upset 500 ± 15 Show/hide tableIllustration 36 g03195541 (11) Extruded
(12) Double upset - Add the correct quantity of oil to the roller.
Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for proper fill volumes and oil types. Also refer to Table 9 for oil fill volumes.
Note: Oil fill volumes are dependent upon shaft configuration. Refer to Illustration36 to determine shaft type, and refer to Table 9 for proper oil fill volume-based upon shaft configuration. Variation in shaft configuration applies only to the model numbers contained in Table 9.
Show/hide tableTable 10 Plug Depth Specifications Model Usage Plug Height Above
Stopper SurfaceAll models 0.0 ± 5.0 mm (0 ± 0.20 inch) Show/hide tableIllustration 37 g02420127 Insert plug into stopper. - Use the 5P-7419 Installer Tool to insert the plug into the stopper to the plugs proper depth. (Refer to Table 10 for proper plug depth specifications.)
Note: The plug must not be recessed below the stopper surface after assembly.
Show/hide tableIllustration 38 g02420128 Tap end of roller shaft to confirm if roller contains oil. - Tap the end of the roller shaft to confirm that there is oil in the roller. If there is a dull thud, the roller contains oil. If there is a ringing noise, the roller is empty.
Illustration 11 | g02420085 |
Factory finish for shaft ramp area. |