RENR3962-02

Disassembly and Assembly Procedures Reconditioning

for Snap Ring and Oval Track Rollers

Disassembly
1. Reference Material
Form Number Title

SEBF8579 Snap Ring Roller Disassembly and Assembly Procedures

Step Procedure Reference/Tool Required Critical SEBF8588 Oval Track Roller Disassembly and Assembly Procedures
SEBF8511 Reusability and Assembly Recommendations for Duo-Cone Seals
1 Remove plug and stopper, then Drill with a .5 inch drill bit. NECG0604 Tool Guide
drain oil. Oil Fill Volume for Track Rollers
SEBF8574
2 Compress the roller using a press Use a hydraulic press. SEHS8484 Tool and Specification Chart for Conventional Duo-Cone Seals
or tooling and use a screwdriver
SEHS8364 Assembly and Installation for Conventional Duo-Cone Seals
to remove the retaining rings in
the end collar. SEHS8354 Cleaning Guide: Equipment and Chemical Recommendations for the Track Shop
3 Remove both end collars. End Collar SEBF8596 Guideline for Reusable Roller and Idler Components
(See Illustration 1)
4 Remove the Duo-Cone seals from SEBF8511-proper reuse Q 2. Tooling Reference
Press Press Ram
the end collars and roller shell, and information for DuoCone Ram Description Part Number Description Part Number
inspect them for reuse criteria. seals.
NOTE: Reused Duo-Cone seals D5M, D5C, D4H Roller Assembly Tool 126-4045 Snap Ring Pliers 5P-4758
must be kept in pairs. 166-5902 O-Ring Compound 1U-6395
5 Measure shaft-to-bearing Use a feeler gauge. See D6M, D5H, 953 Roller Assembly Tool 123-6692
Plug Installation Tool 5P-7419
clearance. Table 5 or 8 for specifications. D6R, D6H, 963 Roller Assembly Tool 123-6693
6 Unload the snap rings by pushing See Table 2 for correct D7R, D7H, 973 Roller Assembly Tool 123-6699
against the bushing with the tooling.
installation tool.
(See Illustration 2)
Assembly Tool
Snap Ring Rollers
7 Remove the snap rings or bolts Use 5P-4758 Snap Ring
from both ends of the roller. Pliers. 1 Remove the end collars using a
2 Unload the snap rings by pushing
3. Seal Installer Tooling 4. Plug Depth Specifications
8 Press on the shaft to remove the
first bushing. hydraulic press. against the bushing with the Model Usage Installer Part Number Model Usage
Plug Height Above
Stopper Surface
Rotate the roller end for end and
installation tool.
9
D7R, D7H, D6R, D6H, 983, 1U-8840
remove the other bushing and the All Models 0 - 5 mm
973C, 973, 963C, 963B, (0 - .20 in)
shaft.
963, 572R, 527
D6M, D5M, D5H, D4H, 1U-8843
953C, 953B, 953, 943,

Preparation for Assembly

939C, 939, 517

5. Snap Ring Specifications

Roller Roller Endplay Shaft/Bearing
Model Oil Volume Oil Weight CAT Part #
Assembly Group Tolerances Clearances
Step Procedure Reference/Tool Required Critical 973 124-8255 DF 134-6637 420 ± 25 ml SAE 30 8C-3698 0.26/1.24 mm 0.68/0.84 mm
973C 124-8251 SF 134-6636 (.0102/.0488 in) (.0264/.0331 in)
10 Wash and remove all debris from 124-8255 DF 124-8253
roller. 124-8251 SF 124-8250
11 973 124-8255 DF 129-5030 4 20 ± 25 ml SAE 30 8C-3698 0.26/1.24 mm 0.68/0.84 mm
Clean components with alcohol Use lint free cloth. 4

Steel Mill 124-8251 SF 129-5029 (.0102/.0488 in) (.0264/.0331 in)

and dry with a lint free cloth.
973C
12 Install new o-rings in the bushings Use 1U-6395 O-ring Assembly Steel Mill
using o-ring compound. compound. Height 963 120-5767 DF 120-5766 410 ± 25 ml SAE 30 8C-3698 0.25/1.33 mm 0.67/0.83 mm
963B 120-5753 SF 120-5743 (.00984/.0524 in) (.0264/.0327 in)
13 Inspect seals for reusability. SEBF8511 Q 963C
14 Replace toric rings if reusing Duo- Q 953 121-0828 DF 121-0827 300 ± 20 ml SAE 30 8C-3698 0.21/1.29 mm 0.55/0.71 mm
Cone seals. 953B 121-0825 SF 121-0824 (.0083/.051 in) (.0217/.0280 in)
953C
15 Dampen torics with proper lubricant. Use 99% alcohol or
End 953 121-0828 DF 129-2978 300 ± 20 ml SAE 30 8C-3698 0.21/1.29 mm 0.55/0.71 mm
approved assembly lubricant. 953B 121-0825 SF 129-2977 (.0083/.051 in) (.0217/.0280 in)
Collar
16 Install the Duo-Cone seals into the See Table 3 for installation Q 943,943B 124-8241 DF 124-8240 280 ± 20 ml SAE 30 8C-3698 0.25/1.23 mm 0.58/0.70 mm
collars. Use an even, perpendicular tools. 561M 124-8238 SF 124-8237 (.0098/.0484 in) (.0228/.0276 in)
force. 939 124-8241 DF 124-8240 280 ± 20 ml SAE 30 8C-3698 0.25/1.23 mm 0.58/0.70 mm
(See Illustration 3) Installation 939C 124-8238 SF 124-8237 (.0098/.0484 in) (.0228/.0276 in)

3
Tool 572R 124-8255 DF 124-8253 420 ± 25 ml SAE 30 8C-3698 0.26/1.24 mm 0.68/0.84 mm
17 Check the assembled seal height at
four locations 90 degrees apart.
Use 8T-0447 or 8T-0450
Calipers.
Q
Install the Duo-Cone seals into the
4 Check assembled Duo-Cone seal
124-8251 SF
Model Number
120-5767 DF
124-8250 (.0102/.0488 in)
0.25/1.33 mm
(.0264/.0331 in)
527 120-5766 410 ± 25 ml SAE 30 8C-3698 0.67/0.83 mm
The difference in height around the end collars. height at 4 locations 90 degrees 120-5753 SF 120-5746 (.0098/.0524 in) (.0264/.0327 in)
ring must not exceed 1 mm (.04).
apart. D7H 124-8255 DF 134-6637 420 ± 25 ml SAE 30 8C-3698 0.26/1.24 mm 0.68/0.84 mm
(See Illustration 4)
124-8251 SF 134-6636 (.0102/.0488 in) (.0264/.0331 in)
D7R 124-8259 DF 124-8258 420 ± 25 ml SAE 30 8C-3698 0.26/1.24 mm 0.68/0.84 mm
(.0102/.0488 in) (.0264/.0331 in)
D7X,D7R 124-8255 DF 124-8253 420 ± 25 ml SAE 30 8C-3698 0.26/1.24 mm 0.68/0.84 mm

Assembly
D7H 124-8251 SF 124-8250 (.0102/.0488 in) (.0264/.0331 in)
D6R 120-5767 DF 120-5766 410 ± 25 ml SAE 30 8C-3698 0.25/1.33 mm 0.67/0.83 mm
D6H 120-5753 SF 120-5746 (.0098/.0524 in) (.0264/.0327 in)
D6R 120-5804 DF 120-5802 410 ± 25 ml SAE 30 8C-3698 0.25/1.33 mm 0.67/0.83 mm
Step Procedure Reference/Required Tool Critical
Roller Shell (.0098/.0524 in) (.0264/.0327 in)
18 Press bushing into place and use Bearing D6M 121-0828 DF 121-0827 300 ± 20 ml Model 8C-3698
SAE 30 Number 0.21/1.29 mm 0.55/0.71 mm
For snap ring style, see Table
Assembly 121-0825 SF 121-0824 (.0083/.0508 in) (.0217/.0280 in)
the specificed assembly tool to 2 for correct installation tool.
press the bushing into place. For oval track, use plate and 121-0831 DF 121-0830
Press Ram Guide
(See Illustration 5 or 6) guides. Guide D5M 124-8241 DF 124-8240 280 ± 20 ml SAE 30 8C-3698 0.25/1.23 mm 0.58/0.70 mm
Bolts
Plates D5C 124-8238 SF 124-8237 (.0098/.0484 in) (.0228/.0276 in)
19 Rotate the roller end for end and
D5M 124-8248 DF 124-8243 280 ± 20 ml SAE 30 8C-3698 0.25/1.23 mm 0.58/0.70 mm
postition the shaft and other (.0098/.0484 in) (.0228/.0276 in)
bushing into the roller. Toric D5H 121-0828 DF 129-2978 300 ± 20 ml SAE 30 8C-3698 0.21/1.29 mm 0.55/0.71 mm
20 Press the shaft and bushing in Use hydraulic press. Ring 121-0825 SF 129-2977 (.0083/.0508 in) (.0217/.0280 in
using the proper roller assembly 121-0828 DF 121-0827
tool. D4H 124-8241 DF 124-8240 280 ± 20 ml SAE 30 8C-3698 0.25/1.23 mm 0.55/0.71 mm
21 Install new o-rings on the shaft Use 1U-6395 O-ring 121-0825 SF 121-0824 (.0098/.0484 in) (.0217/.0280 in)
using o-ring compound. compound. Assembly
22 Compress and install the snap rings
or install the bolts into each end.
Use 5P-4578 Snap Ring
Pliers.
Tool

Bushing
Oval Track Rollers
(See Illustration 7 or 8) 5 Use the correct tooling to press the
6 Use the correct tooling to press the 6. Torque for Retaining Bolts 7. Seal Installer Tooling
23 Use alcohol to clean the seal ramp bushing into place. bushing into place.
area where the rubber toric ring of Dynamic Static
Model Usage
Installer Part
the Duo-Cone seal will set. Assembly Assembly Number
Model Usage Torque Torque
24 Dampen torics with proper lubricant. Use 99% alcohol or N·m (lb-ft) N·m (lb-ft) D6R, D6M, D6H, D6D, D6C, D5M, 1U-8843
approved assembly lubricant. 983B, 983, 245 135 ± 20 115 D5H, D5B, D5, D4H, D4D, D3, 963,
Snap Ring Pliers 961, 955K, 955L, 955, 953, 951C,
25 Install the seals into the bushings. Q (99 ± 14.8) (84.8)
951B, 951, 943, 941B, 941, 939,
Use an even, perpendicular force. D7R, D7G, D7F, D6R, 50 ± 10 40 931, 561M, 561C, 527, 235, 225,
26 Q D6G, D6E, D6D, D6C, (36.9 ± 7.4) (29.5) 219, 215SA, 215B, 215
Check the assembled seal height at Use 8T-0447 or 8T-0450
D5B, D5, D4D, D3,
four locations 90 degrees apart. Calipers. D9H, D9G, 594H, 594 1U-8842
977L, 977K, 977, 973,
The difference in height around the 963, 961, 955L, 955K, D8K, D8H, 583K, 583H 1U-8841
ring must not exceed 1 mm (.04). 955, 953, 951C, 951B, D7R, D7H, D7G, D7F, D6D, D6C, 1U-8840
27 Wipe the entire Duo-Cone seal face Q 951, 943, 941B, 941, 983B, 983, 977L, 977K, 977, 973,
in the bushings and end collars with 931, 572, 561C, 235, 572, 245, 235
a lint free cloth. 227, 225, 219, 215SA,
215B, 215
28 Apply a thin film of oil to the entire Use a horse-hair brush. Q Snap Ring Bolts D9H, D9G, D8K, D8H, 105 ± 20 85
Duo-Cone seal face.
594H, 594, 583K, (77.4 ± 14.8) (62.7)
(See Illustration 9) 583H
29 Install the end collars. 7 Install snap rings.
8 Install the bolts.
30 Compress the roller and replace the Use a hydraulic press. 8. Oval Track Specifications
retaining rings in the end collars.
Duo-Cone Model Roller Roller Oil CAT Endplay Shaft/Bearing
(See Illustration 10) Collar Collar Seal Usage Assembly Group Oil Volume Weight Part # Tolerances Clearance
Seal Face
That Gets 983B, 9P-1449 DF 123-1188 300 ± 15 ml SAE 30 8C-3698 0.25/0.89 mm 0.30/0.41 mm
Oiled Roller 983, 245 9G-7046 SF 123-1186 (.0098/.0350 in) (.0080/.0058 in)
Shell
Press 9P-1449 DF 9P-1451 2P-9869
Ram Locking 9G-7046 SF 9G-7045
Ring 9P-1449 DF 9P-1514 2P-9869
9G-7046 SF 9P-1515
9G-7046 SF 128-8829 8C-3698
D6C, D4D, 9P-7782 SF 118-1608 280 ± 20 ml SAE 30 8C-3698 0.26/0.96 mm 0.58/0.69 mm
D3, 941B, (.0102/.0378 in) (.0228/.0271 in)
941, 931,
225, 219,
215SA, 215
D6C, D4D, 9P-7786 DF 118-1609 280 ± 20 ml SAE 30 8C-3698 0.26/0.96 mm 0.55/0.71 mm
D3, 943, (.0102/.0378 in) (.0217/.0280 in)
End Collar
931B, 941,

9 Apply a thin layer of oil to entire

10 Install end collar locking ring.
931
D5, 961, 9S-9535 SF 118-1611 300 ± 20 ml SAE 30 8C-3698 0.26/0.93 mm 0.55/0.71 mm
955L, 955K, 9S-9534 DF 118-1612 (.0102/.0366 in) (.0217/.0280 in)
seal ring face. 955, 951C,
951B, 951,

Test and Lubricate

561C, 219,
215SA,
215B, 215
D5B, 953, 9W-8353 SF 118-1632 300 ± 20 ml SAE 30 8C-3698 0.26/0.93 mm 0.67/0.83 mm
951 9W-8350 DF 118-1633 (.0102/.0366 in) (.0264/.0327 in)
Step Procedure Reference / Tool Required Critical
D6C, 955, 6Y-2902 SF 118-1614 410 ± 25 ml SAE 30 8C-3698 0.27/0.93 mm 0.68/0.84 mm
30 Lubricate the stopper. Install it Use a light oil to lubricate 235 6Y-9204 DF 118-1615 (.0106/.0366 in) (.0268/.0331 in)
20 30
20 30

10 40
10 40

0 50
0 50

7 ± 7 mm (.3 ± .3 in) below the stopper. Pressure D6G, D6E, 410 ± 25 ml 8C-3698 0.27/0.93 mm 0.68/0.84 mm
8T-0831 9G-8027 SF 118-1617 SAE 30
shaft chamfer. Differential D6D, D6C, (.0106/.0366 in) (0.268/.0331 in)
9G-8032 DF 118-1618
O
--M- He
Cycleat
Reset
//

Gauge
Purge

227
31 Use the (170-5664) Test and Fill If using FT2724, do not allow QQ
40

D6R, D6D, 9W-5408 SF 118-1634 410 ± 25 ml SAE 30 8C-3698 0.27/0.93 mm 0.68/ 0.84 mm
50

machine to evaluate and fill the nitrogen to enter in a surge 170-5665

30

963, 955 9W-5411 DF 118-1635 (.0106/.0366 in) (.0268/.0331 in)

20

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

0
10

perform the following test using the excess of 138 kPa (20 psi), D6D, D6C, 9G-8027 SF 122-0216 410 ± 25 ml SAE 30 8C-3698 0.27/0.93 mm 0.68/0.84 mm
FT2724. Introduce nitrogen into as this may displace the toric 955L, 955K 9G-8032 DF 122-0217 (.0106/.0366 in) (.0268/.0331 in)
40

the lubricant cavity to a pressure ring. D6D, D6C, 9S-9401 SF 9S-9403 416 ± 25 ml SAE 30 8C-3698 0.28/0.92 mm 0.68/.084 mm
50
30

Ball Valve 235 9S-9402 DF 9S-9404 (.0110/.0362 in) (.0268/.0331 in)

of 138 kPa (20 psi). Next close the
20

110
0

pressure differential gauge. The D7G, D7F, 4S-9049 SF 118-1623 420 ± 25 ml SAE 30 8C-3698 0.26/0.92 mm 0.68/0.84 mm
0 220
10

Step pressure is Procedure

to be observed for 10 Reference / Tool Required Critical 977L, 977K, (.0102/.0362 in) (.0268/.0331 in)
seconds. A pressure drop of 2.5 Pressure Gauge 235
percent (3.5 kPa/0.5 psi) or less D7G, D7F, 8S-2931 DF 118-1625 420 ± 25 ml SAE 30 8C-3698 0.26/0.92 mm 0.71/0.94 mm
is acceptable. 977L, 977K, (.0102/.0362 in) (.0280/.0370 in)
(See Illustration 11 & 12) 973, 572

32 Add proper oil volume to the roller. See Table 5 or 8 for correct 11 Use the (170-5664) Test and Fill
12 Pressure test the roller using FT2724.
D7R, D7G,
977, 973
9W-8359 SF 118-1636
9W-8356 DF 118-1637
420 ± 25 ml SAE 30 8C-3698 0.26/0.92 mm
(.0102/.0362 in)
0.71/0.94 mm
(.0280/.0370 in)
oil fill volume.
Machine to evaluate and fill the joint. Introduce nitrogen into the lubricant D9H, D9G, 8P-5486 SF 7G-2762 677 ± 14 ml SAE 30 2P-9869 0.35/0.93 mm 0.71/0.94 mm
33 Check the endplay of the roller. See Table 5 or 8 for endplay 594H, 594 8P-8485 DF 7G-2763 (0.138/.0366 in) (.0280/.0370 in)
tolerances.
cavity to a pressure of 138 kPa
8P-5486 SF 7G-8807 660 ± 30 ml 5W-40 109-6411
(20 psi). Next close the pressure
34 Insert the plug into the stopper to Specifications for proper 8P-5485 DF 7G-8808
the proper depth. plug depth are in Table 4.
differential gauge. The pressure is to 8P-5486 SF 8P-5604 660 ± 30 ml SAE 30 8C-3698
be observed for 10 seconds. A 8P-8485 DF 8P-5405
35 Tap the roller rim to check for oil. If Use a small hammer. pressure drop of 2.5 percent D8K, D8H, 7G-8805 SF 7G-8809 0W-30 0.25/0.74 mm 0.71/0.81 mm
514 ± 11 ml 5P-5289
there is a dull thud, the roller (3.5 kPa/0.5 psi) or less is acceptable. 583K, 583H 7G-8806 DF 7G-8810 (.00984/.029 in) (.0280/.0319 in)
contains oil. If there is a ringing
noise, the roller is empty.

RENR3962-02
Reconditioning
©2004 Caterpillar Inc.
Printed in U.S.A. (6/04)