RENR3960-02

Disassembly and Assembly Procedures Reconditioning

for Idlers with Conventional Duo-Cone Seals

Disassembly 1. Reference Material
Title
Form Number

Step Procedure Reference/Tool Required Critical SEBF8585 Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals
SEBF8511 Reusability and Assembly Recommendations for Duo-Cone Seals
1 Remove plug and stopper. Then Drill with a .5 inch drill bit.
drain oil. SEBF8515 Repair Procedures for Retainer Assemblies on Track Rollers and Idlers
2 Remove retainer bolts. SEBF8364 Assembly and Installation of Conventional Duo-Cone Seals
SEBF8484 Tools and Specification Chart for Conventional Duo-Cone Seals
3 Remove end collar. Use a hydraulic press.
(See Illustration 1) SEBF8576 Oil Fill Volume for Idlers
4 Remove retainer. SEBF8596 Guideline for Reusable Roller & Idler Components
5 Remove thrust washers. Shaft-to-Bearing
Clearance
6 Measure inside collar diameter. See Table 3 for the inside Bearing 2. Tooling Reference 3. Collar Specifications
collar diameter
specifications.
Seal Installer Model Number Part Number Inside Diameter
7 Measure shaft/collar interface See Table 4 for the shaft
diameter. dimensions at the Model Number Tooling Part Number D11R, D11N 156-4653 100.40 ± 0.02 mm
shaft/collar interface. (3.95 ± 0.001 in)
D11R, D11N 159-9843
8 Remove O-rings from retainer. Shaft D10R, D10N, 107-9620 74.40 ± 0.02 mm
D10R, D10N, D9L 129-1340
D9L (2.93 ± 0.001 in)
9 Remove O-rings from end collars. D9R, D9N, D8R, D8N, D8L, 227-4755
583X, 583R, 578 D10R, D10N, 107-3947 68.40 ± 0.02 mm
10 Remove Duo-Cone seals from Idler D9R, D9N, (2.69 ± 0.001 in)
retainers and end collars. D7R, D7H, D6R, D6H, 572R, 224-9467
2
D9L, D8R,
11 Inspect the set of Duo-Cone seals SEBF8511-proper reuse Q 1 Remove the end collars using a Measure shaft-to-bearing clearance.
527
D6M, D5M, D5H, D4H, 561 179-7208
D8N, D8L,
side by side for reusability. information for Duo-Cone 583X, 583R,
NOTE:Seals must be kept in seals. hydraulic press. 578
matching pairs if reused. Seal Height Tooling
D9R, D9N, 107-3945 58.40 ± 0.02 mm
12 Measure shaft to bearing See Tables 5,6, and 7 for Q All Models 8T-0450 D8R, D8N, (2.30 ± 0.001 in)
clearance. clearance specifications. (8T-0447 Calipers) D8L, D7R,
(See Illustration 2) D7H, D6R,
Miscellaneous Tooling D6H, 583X,
13 Remove shaft from idler. Use a hoist if necessary. 583R, 578,
Description Tooling Part Number
572R, 527
Plug Installation Tool 5P-7419 D6M, D5M, 160-9756 46.40 ± 0.02 mm
D5H, D4H, 561 (1.83 ± 0.001 in)
O-ring Compound 1U-6395

Preparation for Assembly 4. Shaft Dimensions at

5. Shaft/Bearing Clearance
Collar/Shaft Interface
Shaft Part Clearance
Step Procedure Reference/Tool Required Critical Model Number Outside Diameter Model Number
Number (min/max)

14 Wash and remove all debris from D11R, D11N 156-5351 100.50 ± 0.02 mm D11R, D11N, D10R, D10N, 0.44 / 0.56 mm
idler. (3.96 ± 0.001 in) D9R, D9N, D9L, D8R, D8L, (.0173 / .0220 in)
D10R, D10N, D9L 154-3308 74.50 ± 0.02 mm D7R, D7H, 583X, 583R,
15 Clean and dry components. Make Use a lint free cloth.
(2.93 ± 0.001 in) 578, 572
sure all oil residues are removed. Assembly
Height D9R, D9N, D8L 154-3309 68.50 ± 0.02 mm D6R, D6H, 527 0.30 / 0.40 mm
16 Install O-rings in retainers and end Use 1U-6395 O-ring (.0118 / .0157 in)
(2.70 ± 0.001 in)
collars using O-ring compound. compound.
D9N, D8R, D8N, D8L, 154-3307 68.50 ± .02 mm D6M, D5H 0.30 / 0.52 mm
17 Inspect seals for reusability. Q
Q (.0118 / .0205 in)
583X, 583R, 578 (2.70 ± 0.001 in)
18 Replace toric rings if reusing seals. D5M, D4H, 561 0.26 / 0.48 mm
D7R, D7H, 572 131-3935 58.50 ± 0.02 mm
19 Dampen toric with proper Use 99% isopropyl alcohol (2.30 ± 0.001 in) (.0102 / .0189 in)
lubricant. or approved assembly 149-2494 58.50 ± 0.02 mm
D6R, D6H, 527
lubricant.
20 Install seal using proper installation See Table 2 for installation Q
Q 4 D6M, D5H 161-7350
(2.30 ± 0.001 in)
46.50 ± 0.02 mm
tool into end collars and retainers. tools. (1.83 ± 0.001 in)
(See Illustration 3)
21 Check assembled seal height in See Table 2 for proper seal Q
Q 3 Install Duo-Cone seals into retainers
4 Check assembled seal height in
D5M, D4H, 561 160-9757 46.50 0.02 mm
(1.83 ± 0.001 in)
end collars and retainers at four height tooling.
locations 90 degrees apart. The and end collars using the proper the retainer at 4 locations 90
difference in height must not installation tool. Use a sudden, degrees apart. 6. Idler Rebuild Dimensions
exceed 1.0 mm (0.039 in). even, perpendicular force to install
(See Illustration 4) the seals. Model Number
Idler Bore Idler Hub Bearing Idler Assembly Bore
Diameter (mm) Width (mm) Part Number Diameter (mm)
Model Number
D11R, D11N 168.89 ± 0.04 402.00 ± 0.13 148-3540 162.77 ± 0.03
D10R, D10N, D9L 142.85 ± 0.04 326.00 ± 0.13 9W-4194 136.78 ± 0.03

Assembly D9R, D9N, D8L

D9N, D8R, D8N, D8L,
578 (front)
133.32 ± 0.04
133.32 ± 0.04
290.00 ± 0.13
290.00 ± 0.13
9W-9499
9W-9499
127.25 ± 0.03
127.25 ± 0.03

D8R, D8N, 583X, 583R, 133.32 ± 0.04 250.00 ± 0.13 154-3298 127.25 ± 0.03
Step Procedure Reference/Required Tool Critical 578 (rear)
Duo-Cone D7R, D7H, 572R (E W) 133.32 ± 0.04 216.00 ± 0.13 154-3298 127.25 ± 0.03
22 Lightly lubricate the bearings with Retainer Seal Seal Face That
Gets Oiled D7R, D7H 133.32 ± 0.04 216.00 ± 0.13 6Y-1757 127.25 ± 0.03
the same oil type used to fill the
idler. D6R, D6H, 527 114.28 ± 0.04 199.00 ± 0.13 6Y-1757 108.06 ± 0.02
23 Install shaft into idler. Use hoist if necessary. D6M, D5H 102.00 ± 0.04 189.00 ± 0.13 9P-2245 95.84 ± 0.08
24 Install thrust washers on each end D5M, D4H, 561 (rear) 96.00 ± 0.04 168.00 ± 0.13 9P-1360 89.67 ± 0.08
of idler. (Some thrust washers are 8P-7002 89.67 ± 0.08
D5M, D4H, 561 (front) 96.00 ± 0.04 168.00 ± 0.13
pinned.) Toric
Ring
25 Slide retainer over shaft and move
to final position.
7. Shaft Specifications
26 Install and tighten retaining bolts.
27 Torque bolts to proper See Table 8 for torque Model Number Idler Shaft Part Outer Shaft Bearing Surface Length
specifications. specifications. Assembly Number Diameter (mm) (mm)

28 Lightly wipe the entire Duo-Cone Use a clean, dry, lint free Q D11R, D11N 148-3730, 187-1011 156-5351 162.27 ± 0.03 377.0 ± 0.10
5 6
Shaft
seal ring face in retainers and end cloth. D10R, D10N, D9L 7T-0961 154-3308 136.28 ± 0.03 301.0 ± 0.10
collars. Wipe the seal face using a lint Apply a thin layer of oil to entire D9R, D9N, D8L 7T-2770 154-3309 126.75 ± 0.03 265.0 ± 0.10
(See Illustration 5) free cloth. seal ring face.
D9N, D8R, D8N, 6Y-0556 154-3307 126.75 ± 0.03 225.0 ± 0.10
29 Apply a light film of oil to the entire Use a horse-hair brush. Q D8L, 578 (front)
Duo-Cone seal face. D8R, D8N, 583X, 6Y-0553 154-3307 126.75 ± 0.03 225.0 ± 0.10
(See Illustration 6) 583R, 578 (rear)
30 Position end collar assembly Spin Socket D7R, D7H, 159-2084, 192-0215 131-3935 126.75 ± 0.03 191.0 ± 0.10
against retainer. 572R (E W)
31 Press end collar into place. Use a hydraulic press. D7R, D7H 6Y-2030 131-3935 126.75 ± 0.03 191.0 ± 0.10
(See Illustration 7) See Table 9 for correct
end collar driver tool. D6R, D6H, 527 6T-3217, 7T-8940 149-2494 107.71 ± 0.03 160.0 ± 0.05

32 Repeat for other end collar. D6M, D5H 186-3589, 190-1547 161-7350 95.43 ± 0.03 150.0 ± 0.10

33 Spin the shaft 20 revolutions in See Table 10 for correct Q D5M, D4H, 561 186-3566, 190-2495 160-9757 89.30 ± 0.03 129.0 ± 0.10
each direction. spin socket tooling. (front & rear)
(See Illustration 8) D5M, D4H, 186-3584, 190-1536 160-9757 89.30 ± 0.03 129.0 ± 0.10
561 (rear)
34 Check endplay. See Table 11 for endplay Shaft
tolerances.

8.Torque for Retaining Bolts 9. End Collar Tooling

7 Press the end collar into place.
8
Spin shaft 20 revolutions in both Dynamic Static Inspection
Driver Part
directions at no more than 100 rpm. Model Number Torque Torque Model Number Number
N•m (lb-ft) N•m (lb-ft)

D11R, D11N 270 ± 40 230 D11R, D11N 170-5405

(5/8 in. bolts) (200 ± 30) (170)

Test and Lubricate D10R, D10N, D9L

(1/2 in. bolts)
135 ± 20
(100 ± 15)
115
(85)
D10R, D10N, D9L
D9R, D9N, D8L
170-5406
170-5409
D9N, D8R, D8N, D8L, 583X, 170-5408
D9R, D9N, D8R, 85 ± 15 70
583R, 578
D8N, D8L, D7R, D7H, (63 ± 11) (52)
Step Procedure Reference / Tool Required Critical
583X, 583R, 578 D7R, D7H, 572 170-5411
(7/16 in. bolts)
35 Lubricate the stopper. Install it Use a light oil to lubricate D6R, D6H, 527 170-5412
7 ± 7 mm (.3 ± .3 in) below the the stopper. D6R, D6M, D6H, 55 ± 10 45
20 30
20 30

D6M, D5H 201-1581

10 40
10 40

0 50
0 50

Pressure D5M, D5H, D4H, (41 ± 7) (33)

bottom of the shaft chamfer. 8T-0831
O
--M
-
He
Cycleat
Differential 572, 561 D5M, D4H, 561 201-1582
Gauge
Reset

36 Use the Test and Fill machine If using a FT2724, Do not QQ

//
Purge

(3/8 in. bolts)

40

(170-5664) to evaluate and fill the allow air to enter in a surge

50

170-5665
30

joint. If this is not available, and do not use pressure in

20

0
10

perform the following test using the excess of 138 kPa (20 psi), 10. Spin Socket Tooling 11. End Play Tolerances
FT2724. Introduce nitrogen into the as this may displace the
40

lubricant cavity to a pressure of 138 toric ring.

50

Tolerance
30

Ball Valve Model Number Tooling Part Number Model Number

kPa (20 psi). Next close the (min / max)
20

Step pressure differential

Procedure gauge. The Reference / Tool Required Critical
10

110

0 220

D11R, D11N, D10R, 1U-9399

pressure is to be observed for 10 D11R, D11N 0.33 / 1.19 mm
D10N, D9L FT-1909
seconds. A pressure drop of 2.5 Pressure Gauge (.01299 / .04685 in)
D9R, D9N, D8R, 1U-9398
percent (3.5 kPa/0.5 psi) or less D10R, D10N, D9R, 0.31 / 1.21 mm
D8N, D8L, 583X, FT-1910
is acceptable. D9N, D9L, D8L (.01220 / .04764 in)
583R, 578
10
(See Illustration 9 or 10)
37 Add proper oil volume to the idler. See Table 12 for oil fill
9 Use the Test and Fill Machine Pressure test the idler using FT2724.
D7R, D7H, D6R,
D6H, 572, 527
FT-1911
D9N, D8R, D8N, D8L,
583X, 583R, 578
0.38 / 1.14 mm
(.01496 / .04488 in)
volumes. (170-5664) to evaluate and fill the Introduce nitrogen into the lubricant D7R, D7H, 572 0.38 / 1.24 mm
D6M, D5H, D5M, FT-1994 (.01496 / .04882 in)
38 Install the plug into the stopper to a joint. cavity to a pressure of 138 kPa D4H, 561
depth of 0-5 mm (0-.20 in) (20 psi). Next close the pressure D6R, D6H, 527 0.25 / 1.25 mm
above stopper surface. differential gauge. The pressure is to (.00984 / .04921 in)
39 Tap the end of the idler shaft to Use a small hammer. be observed for 10 seconds. A
12. Conventional Idler Oil D6M, D5M, D5H, D4H, 0.38 / 1.24 mm
check for oil. If there is a dull thud, pressure drop of 2.5 percent Fill Volumes 561 (.01496 / 0.4882 in)
the idler contains oil. If there is a (3.5 kPa/0.5 psi) or less is acceptable.
Model Number Oil Fill Volume (ml)
ringing noise, the idler is empty.
D11R, D11N 1700 ± 40
D10R, D10N, D9L 850 ± 20
D9R, D9N, D8L 800 ± 20
D9N, D8R, D8N, D8L, 600 ± 15
583X, 583R, 578
D7R, D7H, 572 650 ± 15
D6R, D6H, 527 540 ± 15
D6M, D5H 440 ± 10
D5M, D4H, 561 362 ± 10
RENR3960-02
Reconditioning
©2004 Caterpillar Inc.
Printed in U.S.A. (8/04)