Removal, Installation, and Conditioning of Idler Bearings and Track Roller Bearings {4159, 4159, 4180, 4180, 7551} Caterpillar

Introduction

© 2020 AVSpare All Rights Reserved. This guideline is for the use of AVSpare 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 AVSpare: 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 AVSpare dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to AVSpare. 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 AVSpare.

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 procedures for idler and track roller bearing removal, installation, and conditioning. The roll-burnishing process and the piloted hone process bearing conditioning methods are covered. Both procedures ensure the proper bearing finish (particularly in the clinch joint area), and the correct bearing alignment.

Photographs throughout this bulletin are of Idlers instead of Track Rollers for simplicity.

References

Reference: Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-ConeSeals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8585, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-ConeSeals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8581, "Disassembly and Assembly Procedures for Track Rollers with Inverted Duo-ConeSeals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8584, "Disassembly and Assembly Procedures for Track Rollers with Conventional Duo-ConeSeals"

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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Example warning

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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.

Required Tooling

Removal of Idler or Track Roller Bearings

Follow the steps below for removal of idler or track bearings.

1. Acquire pusher plate, stopper plate, and stud from table 3.
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   Illustration 3	g02688676

2. As required, install stud (1) into the ram of the idler/roller press.

   Note: 6V-6084 Stud and 8T-7737 Stud must be modified for use on presses that do not have M8 X 2.5-IN threads.

3. Install pusher plate (2) onto stud (1).

4. Press the pusher plate (2) completely through the idler or track roller bore to remove both bearings.

5. Wash the bearing bores with soap and hot water, or clean the bearing bores in a spray washer or agitating washer.

   Note: To prepare for new bearings, make sure that idler or track roller bores are free of any oil residue or foreign material. All parts must also be dry before assembly.

Installation of Idler or Track Roller Bearings

Follow the steps below for installation of idler or track roller bearings. Installed bearings should be roll-burnished or honed as required. (Illustrations show idlers only).

Note: The idler or track roller bores must be free of any oil residue or foreign material. All parts must be dry before bearing installation.

Note: 6V-1541 Quick Cure Primer can be used after washing/drying to speed up hardening of retaining compound. Quick Cure Primer will also help with extra oil and grease removal. Use quick cure primer for temperatures below 10° C (50.0° F).

1. Inspect the clean/dried center bore for damage.

   Note: For correct diameter of center bore in idler, refer to Undercarriage Reconditioning Bulletin, SEBF8571, "Reconditioning Dimensions for Idlers".

   Note: For correct diameter of center bore in track roller, refer to Undercarriage Reconditioning Bulletin, SEBF8569, "Reconditioning Dimensions for Track Rollers".

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   Illustration 4	g02700436

2. Install stopper plate (2) onto stud (1)

3. Install pusher plate (3) onto stud (1).

4. Fasten stopper plate (2) to pusher plate (3) using four 0S-1595 Boltsand four 4B-5273 Washers.

5. Obtain two new idler bearings or track roller bearings. Refer to table 4 or 5 at the rear of this bulletin.

6. Apply a thin layer of Loctite Retaining Compound 609 60931 to the idler or track roller bore and to the OD of the bearing. Apply the retaining compound with a small 25.4 mm (1.00 inch) brush.
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   Illustration 5	g02694757

7. Press the new bearings (2) into the bore until the stopper plate (1) is against the idler hub (3) or against the roller bolt hole face.
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   Illustration 6	g02696776

   Note: Bearing installation is complete when the stopper plate is against the idler hub or against the track roller bolt hole face.

8. Complete bearing installation.

9. Repeat this procedure for the opposite side of the idler or track roller.

10. Allow 2 hours for the bearing retaining compound to cure for strength.

11. Proceed to the bearing conditioning steps to either roll-burnish or hone bearings as required.

Condition the New Idler or Track Roller Bearings

The new bearing must be conditioned after the bearing is installed into the hub using roll-burnishing or pilot honing. Roll-burnishing is a preferred method of bearing conditioning although the initial investment is a major consideration. Roll-burnishing takes less than 1/4 of the time that honing takes, work hardens the bearing, and mechanically joins the bearing to the bore. (no need for retaining compound)

Roll-Burnishing - Bearing Conditioning

Newly installed idler or track bearings should be conditioned by roll-burnishing. Roll-burnishing is the preferred bearing conditioning method.

Secure the Idler or Track Roller to Drilling Table

Follow the steps below to secure the idler or track roller.

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Illustration 7	g02725446

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NOTICE
Avoid stand interference. The roll-burnishing tool must be able to pass completely through the idler bore and not hit the holding stand.

1. Center the idler or track roller on cylindrical stand (1) or a comparable support stand.
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   Illustration 8	g02725453

2. Lock the idler or roller into place using a combination of strap clamps (1), threaded rods (2) and wooden support blocks (3).

3. Obtain the proper roll-burnishing tool. Refer to table 2 at the front of this bulletin.
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   Illustration 9	g02725462

4. Attach the Morse taper extension (1) to the roll-burnishing tool (2). Tap with a lead or brass hammer to insure proper seating.
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   Illustration 10	g02725485

5. Position the roll-burnishing tool (2) and Morse taper extension (1) into the radial drill spindle.
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   Illustration 11	g02725491

6. Tap the end of the burnish tool with a lead or brass hammer to make sure that the taper is seated properly.
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   Illustration 12	g02725494

7. Position the drill directly over the bearings to be roll-burnished.

Burnish the Bearing Bore

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Illustration 13	g02725498

1. Start the lubrication fluid supply. Make sure the fluid flows through the idler or track roller bore.

   Note: Honing oil 5P-8615 is recommended.

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   Illustration 14	g02725517

2. Operate the Burnisher at 210 rpm.

3. Lower the drill through the idler or track roller bore slowly and at a constant rate.

   Note: This burnishing process makes the bearing change shape to conform to the bore of the idler or track roller.

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   Illustration 15	g02725531

4. After burnishing both bearings, raise the drill back through the idler or track roller bore.
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   Illustration 16	g02725536

5. Using a dial bore indicator, check the burnished bearing diameter.

   Note: The bearing diameter should be checked on the inside edge, outside edge, and in the center of the bearing and in multiple orientations.

Honing - Bearing Conditioning

Newly installed idler or track bearings may be honed using the steps below. (Roll-burnishing is the ideal method of bearing conditioning).

Honing Setup

Select the proper honing tooling.

Illustration 17	g02857562
Typical Stone Set

1. Select stone set (depending upon the sales model) from the Honing Tooling & RPM table 6 or 7.

   Note: Select a stone set suitable for the bore size of the idler or track roller needing honed.

   Note: Table 6 and 7 Stone Sets contain 280 grit stones which provide the required surface finish.

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   NOTICE
   Use stones as matched sets. To avoid uneven wear, do not use old stone sets with newer ones. Unsatisfactory bearing finish may occur.

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   Illustration 18	g02725964
   D11N, D11R, D11T, D10 Stone Set with Holder and Set Screws

2. A holding fixture is required for certain large bearings. For D11N, D11R, D11T, D10 rollers, and idlers, install stone sets (2) into a holder (3) and tighten the set screws (1). Refer to illustration 18.
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   Illustration 19	g02723167

3. Prepare to attach the selected stone set. Remove the pinion (3) from the hone body (1) in preparation for the stone set (2).
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   Illustration 20	g02730653
   End view of hone body showing installation of stone sets.

4. Insert all stone sets (1) into the holes (2) of the hone body.
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   Illustration 21	g02723216

5. Compress the stone sets into the hone body firmly and replace the pinion.
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   Illustration 22	g02723256

6. Attach the guide rod (1) to the hone body (2) and tighten the set screws (3).

Select Proper Drill Motor

Honing must be done at the ideal speed in order for the stones to “cut”correctly.

1. Make note of the proper motor rpm for the model and bore size. Refer to tables 6 and 7.

2. Acquire industrial drill motor 9U-5797 110V or 9U-5888 220V.
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   Illustration 23	g02723295
   Arrangement showing linear bearing (2) and U-bolts (1) attached to drill motor auxiliary handle.

3. Modify the drill handle to accept torsion bar as needed.

   Note: See example slide arrangement illustration 23.

Prepare to Hone Bearing Bore

Prepare the Idler or track roller using the following steps:

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Illustration 24	g02725544

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Improper lifting or tie-downs can allow load to shift and cause injury and damage.

1. Position and secure the idler or track roller in a suitable holding fixture.

2. Determine and note the proper finished bearing bore size. Refer to table 4 or 5 for details.
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   Illustration 25	g02725556

3. Use a dial bore indicator to determine the amount of material to be removed from the bearing.

   Note: The bore size should be checked on the inside edge, outside edge, and in the center of the bearing and in multiple orientations.

   Note: Bearings are designed with extra material so that once pressed into the bore, the bearings can be processed to accurate size.

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   Illustration 26	g02726744

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   Illustration 27	g02725569
   Idler Universal Pilot FT-2683.

4. For idlers, install the universal pilot in a vertical position on the back side. Secure the pilot using retainer bolts from the idler assembly.
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   Illustration 28	g02725572

5. Attach honing oil shield and aim nozzle through idler bore.
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   Illustration 29	g02725581

6. On the front side of idler, insert the guide rod through the idler bore and into the proper hole in the universal pilot hole.
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   Illustration 30	g02725582

7. Pull pinion 6.35 mm (0.25 inch) from the hone for course adjustment of the stones. Turn the knurled ring counterclockwise to position stones near the bearing. Replace pinion.
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   Illustration 31	g02725713

8. Install torsion bars (1) on both sides of the stand. Secure the torsion bars by tightening wing screws (2).
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   Illustration 32	g02725724

9. Slide the front stop (1) onto the right torsion bar, but do not tighten the wing screw.

10. Slide the linear bearing (2) attached to the auxiliary drill handle, onto the right torsion bar.
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    Illustration 33	g02725840

11. Insert and tighten the hone into the drill chuck.
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    NOTICE
    To avoid damage, make sure to adjust drill position as per the steps in this document.

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    Illustration 34	g02725845

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    Personal injury can result from an improper honing operation. Extending the honing stones beyond 25 mm (1 inch) of the bearing edge, can cause personal injury and/or damage to the tool could be the result. During operation of the honing tool, do not extend (pull) the honing stones beyond 25 mm (1 inch) of the bearing edge.

12. Position the drill so that the stones overlap the inner side of the bearing by 13 mm (0.5 inch) to 25.4 mm (1.00 inch). Tighten the front stop (1) while the drill is in this position.
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    Illustration 35	g02725873

13. Position the drill so that the stones overlap the outer side of the bearing by 13 mm (0.5 inch) to 25.4 mm (1.00 inch). Slide on and tighten the rear stop (1) while the drill is in this position.
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    Illustration 36	g02725880

14. Make the fine stone adjustments by turning the pinion wing wrench clockwise until the stones are snug against the bearing.

Hone the Bearing Bore

Hone the bearing bore using the steps below:

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Stay clear of the work tool during operation. Entanglement could result in personal injury or death.

1. Activate the honing oil pump. Make sure that oil flows through the idler or track roller bore.

2. After honing oil begins spilling from the bore, start the drill motor rotating in a clockwise direction.

3. Reciprocate the hone back and forth approximately 20 cycles per minute to 30 cycles per minute.

   Note: New stones will wear quickly until the shape matches that of the bearing.

   Note: Glazed (smooth) stones will not cut. Use an abrasive stick to remove the glaze.

4. When the hone becomes easier to reciprocate, expand the stones by applying slight stopping pressure to the handwheel. Turning the hand wheel counterclockwise while the hone is rotating. Refer to illustration 36.

5. Every 30 seconds, use a dial bore indicator to check the diameter of the bearing. Compare to the proper finished bore size on table 4 or 5. Tighten the stones against the bearing as needed.

6. When the proper bore size has been achieved, turn idler around in the stand and repeat the above process on the second bearing.

7. After using the honing tool, clean with hot water, steam, or cleaning solvents.

Reference Section

Refer to the following information for data on tooling and bearings.

Note: In the table below, Roller part numbers include the designation DF (for double flange) and SF (for single flange).