Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-Cone Seals {0599, 0729, 4180, 4180, 7555, 7561} Caterpillar


Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-Cone Seals {0599, 0729, 4180, 4180, 7555, 7561}

Usage:

943 04Z
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; 90L1-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: 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)

Introduction

Table 1
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

Table 2
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 1g02139237

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.

------ 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 3
Required Tools 
Seal Installer 
Model Number  Part Number 
D11N, D11R  8T-0827 
D10, D10N, D10R, D9L, 589, 583R  8T-0829 
D9N, D9R  8T-7641 
D8L, D8N, D8R, 578  8T-0828 
D7H, D6H, D6R, 973, 973 Steel Mill  8T-0939 
963, 963B  8T-0940 
D5H, D4H, 953, 953B, 943, 943B, 939  8T-0942 
Seal Height Tooling 
All Models  8T-0447 
Miscellaneous Tooling 
Part Description  Part Number 
Plug Installation Tool  5P-7419 
Stopper Installation Tool Group  5P-7392 
O-ring Assembly Compound  369-9450 

Disassembly



    Illustration 2g02420076
    Remove plug and stopper.

  1. Drill out the plug from the end of the shaft with a 0.5 inch drill bit to drain the oil.


    Illustration 3g02420077
    Remove bolts and retainers.


    Illustration 4g02420078
    Remove thrust washers.

  2. 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.



    Illustration 5g02420079
    Remove seals from retainers.

  3. 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.



    Illustration 6g02420080
    Remove the Duo-Cone seals from the roller shaft.

  4. Remove the Duo-Cone seals from the roller shaft and retainer assemblies.


    Illustration 7g02420081
    Remove retainer seals.

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


    Illustration 8g02420082
    Remove toric stabilizers.

  6. Remove the toric stabilizers from both sides of the track roller.

    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 Mill 
    0.44 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) 

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


    Illustration 9g02420083
    Remove the shaft.

  8. 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 10g02420084
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.



    Illustration 11g02420085
    Factory finish for shaft ramp area.

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


    Illustration 12g02420086
    Clean components with a lint free cloth.

  2. Use alcohol or other approved cleaning agents to clean the roller components. Dry with a lint free cloth.


    Illustration 13g02420087
    Install O-rings into retaining grooves.

  3. Use 369-9450 O-ring Assembly Compound to install the new O-rings into the retaining grooves.

    Note: Always use new rubber components.



    Illustration 14g02420088
    Install seals into retainers.


    Illustration 15g02420089
    (1) Retainer

  4. 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.


    Illustration 16g02420090
    Check retainer seal height.


    Illustration 17g02429416
    Check retainer seal height.
    (A) Retainer seal height
    (1) Retainer
    (2) Retainer seal

  5. 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.


    NOTICE

    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.




    Illustration 18g02420092
    Install shaft.

  6. Install the shaft into the track roller.


    Illustration 19g02420093
    Install the toric stabilizers.


    Illustration 20g02420094
    (3) Shaft
    (4) Toric stabilizer

  7. 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.)


    Illustration 21g02420095
    Install thrust washers.

  8. Install the thrust washers on both ends of the track roller shaft.


    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.




    Illustration 22g02420096
    Assemble shaft seal.
    (5) Seal ring
    (6) Toric ring
    (7) Retaining lip
    (8) Seal ring ramp

  9. 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.


    Illustration 23g02420097
    Install Duo-Cone seals onto shaft.

  10. 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.


    Illustration 24g02420098
    Check seal height on shaft.


    Illustration 25g02420099
    Check seal height on shaft.
    (B) Shaft seal height
    (9) Shaft seal face
    (10) Thrust face

  11. 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.



    Illustration 26g02420100
    Wipe shaft seal ring face with lint free cloth.

  12. 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.

  13. Apply a thin layer of oil to the entire face of the seal rings.


    Illustration 27g02420117
    Wipe entire retainer seal face with lint free cloth.

  14. Wipe the entire retainer seal face with a lint free cloth.

    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, 963B 
    8T-0822 
    D5H, D4H, 953, 953B,
    943, 943B, 939 
    8T-0945 


    Illustration 28g02420118
    Slide on the retainer.

  15. 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.)

    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) 


    Illustration 29g02420119
    Tighten two retaining bolts opposite to each other.


    Illustration 30g02420120
    Torque retaining bolts to proper specifications.

  16. 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.

    Table 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, 578 
    FT-1911 
    D5H, D4H, 953, 953B,
    943, 943B, 939 
    FT-1984 


    Illustration 31g02420121
    Spin the shaft.

  17. Select the correct spin socket from Table 7 and spin the shaft 20 revolutions in each direction at less than 100 rpm.

    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 Mill 
    0.25 to 1.25 mm (0.010 to 0.050 inch) 
    D9L, 589, D6H,
    D6R, 963, 963B,
    D5H, 953, 953B,
    D4H, 943, 943B, 939 
    0.25 to 0.85 mm (0.010 to 0.033 inch) 

  18. Check the end play.


    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.




    Illustration 32g02420122
    Install stopper.

  19. 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.


    Illustration 33g02420123
    Use the 170-5664 Test and Fill Cart Gp to evaluate and fill the roller.


    Illustration 34g02420124
    Pressure test the roller using FT-2724 Pressure Gauge Tool Gp.


    Illustration 35g02442296
    Pressure testing tool Ft2724

  20. 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.

    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
    D10R 
    7T-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, 578 
    6T-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 


    Illustration 36g03195541
    (11) Extruded
    (12) Double upset

  21. 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.

    Table 10
    Plug Depth Specifications 
    Model Usage  Plug Height Above
    Stopper Surface 
    All models  0.0 ± 5.0 mm (0 ± 0.20 inch) 


    Illustration 37g02420127
    Insert plug into stopper.

  22. 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.



    Illustration 38g02420128
    Tap end of roller shaft to confirm if roller contains oil.

  23. 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.

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