RENR3964

Reconditioning
Disassembly and Assembly Procedures
for Hydraulic Excavator Idlers
1. Reference Material
Disassembly Title
Form Number

Step Procedure Reference / Tool Required Critical SEBF8511 Reusability and Assembly Recommendations for Duo-Cone Seals
1 Remove plug and stopper or Drill with a .5 inch drill bit or SEBF8484 Tools and Specification Chart for Conventional Duo-Cone Seals
drain/fill set crew (located in idler use allen wrench to remove SEBF8364 Assembly and Installation of Conventional Duo-Cone Seals
hub), then drain the oil. set screw.
NECG0604 Tool Guide
2 Remove retaining ring or pin. Screwdriver or punch.
SEBF8576 Oil Fill Volume for Idlers
3 Remove the end collar. Use a hydraulic press or
(See Illustration 1) large gear puller. SEBF8596 Guideline for Reusable Roller and Idler Components

4 Remove the o-ring from the shaft. SEBF8495 Hydraulic Excavator Idler Disassembly and Assembly Procedures
Shaft-to-Bearing
5 From other side of idler, slide the Clearance
end collar and shaft out of the idler
assembly. 2. Tooling Reference 3. Shaft/Bearing Clearance
6 Remove o-rings from end collars.
7 Remove Duo-Cone seals from Shaft Seal Height Tooling Model Number Clearance (min/ max)
end collars and roller assembly.
215B, 219, 219D, 225, 0.35 / 0.46 mm
8 Inspect the set of Duo-Cone seals SEBF8511-proper reuse Q Bearing Idler All Models 8T-0450 225B, 225D, 227, 229, (0.0138/0.018 in)
side by side for reusability. information for Duo-Cone 8T-0447 Calipers 229D, 235, 235B, 235C,
NOTE: Seals must be kept in seals. 231D
matching pairs if reused. Miscellaneous Tooling
205, 205B, 211, 211B, 213, 0.25 / 0.48 mm
9 Measure shaft to bearing See Table 3 for shaft to Q 213B, 215B, 215C, 215D, (.00984/.0189 in)
clearance.
NOTE: If one or both bearings fail,
bearing clearance 1 Remove end collar using a hydraulic
2 Measure shaft-to-bearing clearance.
Description Tooling Part Number
235C, 235D, 245, 245B,
specifications. Plug Installation Tool 5P-7419 245D, 320, 320S, 320B,
the feeler guage test use bearing press. 322, 322B, 325, 325B,
removal adapter (FT2209 shaft Stopper Installation Tool 5P-7392 330, 330B, 350, 375, 385
with FT2210, FT2211, or FT2212 Bearing Driver Group 1P-0520 231D, 307, 307B, 308B, 0.10 / 0.27 mm
driver) and press to remove both
312, 312B (.0039/.0106 in)
bearings.
(See Illustration 2) 315, 315B, 317, 318, 0.27 / 0.42 mm
318B, 320, 320B (.0106/.0165 in)
4. Seal Installers
Model Number Part Number

7. Plug Part Numbers

Preparation for Assembly 365BL, 375, 385, 5080,
5090
345B, 350
9U-7538

4C-6206 Model Usage Part Number

330, 330 B 1U-8849 205, 205B, 211, 211B, 213, 7H-3171

Step Procedure Reference / Tool Required Critical
311, 311B, 312, 312B, 313B 1U-8850 213B, 307, 307B, 311, (Threaded Type)
10 Wash and remove all debris from 307, 307B 123-3801 311B, 312, 312B, 313,
idler. 313B, 315, 315B, 317,
215, 215B, 219, 219D, 225, 1U-8842 317BL, 317BLN, 317N,
11 Clean components with alcohol Use a lint free cloth. 225B, 225D, 227, 229,
and dry with a lint free cloth. 318B, 318BL, 318BN, 320,
229D, 231D, 315, 315B, 320B, 320C, 320S, 322,
12 Inspect seals for reusability. Assembly 317BL, 317BLN, 317, 317N,
Height 322B, 325, 325B, 330,
Use 1U-6395 O-ring 318B, 318BL, 318BN, 320B, 330B, 345B, 350, 365BL,
13 Install o-rings in the end collar Q
compound. 320, 320C, 320 375, 385
using the o-ring compound.
320S, 322, 322B, 325, 325B 9U-7537
14 Replace toric rings if reusing seals. 245, 215SA, 219, 225 6Y-0473
205, 205B, 211, 215C, 215D 1U-8841 (Bullet Type)
15 Dampen toric with proper lubricant. Use 99% isopropyl alcohol or Q
approved assembly lubricant. 235D, 245, 245B, 245D 1U-6443 215SA, 219, 225, 225SA, 2P-0347
227, 231D, 235, 235D, 245 1U-8840 FB227, 229, 231, 235, 245 (Threaded Type)
16 Install seals into end collars and See Table 2 for installation Q Carefully clean shaft without Check assembled seal height in the
idler assemblies using the proper tools. 205, 211, 213 9W-2146
degrading the seal ramp surface. retainer at 4 locations 90 degrees
installation tools. 215 9F-2247
(See Illustration 3) apart.
215 7G-4408
17 Dry the Duo-Cone seals using Will not need to be done if 5. Endplay Tolerances
pressurized air at 30 psi for 1 using 99% isopropyl alcohol. 3 Install Duo-Cone seals into end
4 Check assembled seal height in the
minute. Model Number Tolerance (min/ max)
18 Check assembled seal height in See Table 2 for proper seal collars and roller assemblies using retainer at 4 locations 90 degrees
end collars and assemblies at four height tooling. the proper installation tool. Use a apart. All Models 0.25 / 1.25 mm
locations 90 degrees apart. The sudden, even, perpendicular force to (.009843 / .04921 in)
difference in height must not install the seals.
exceed 1.0 mm (0.039 in).
(See Illustration 4)
6. Stopper Part Numbers
Model Usage Part Number

Assembly 215, 215SA, 219, 225 7G-4332

245 9G-5664
Step Procedure Reference / Tool Required Critical
Seal Face
19 Lightly lubricate the bearings with Use a horse hairbrush. That Gets
the same oil type used to fill the Oiled 8. HE Oil Fill Volumes
idler.
Wipe the entire Duo-Cone seal ring Seal Face Model Number Idler Group Oil Volume (ml) Oil Weight CAT Part Number
20
That Gets
face in end collars and idler
Oiled 385, 375 135-8904 1300 ± 65 ml SAE 30 8C-3698
assemblies.
134-3005
(See Illustration 5)
Shaft 102-8136 1300 ± 65 ml SAE 30 8C-3698
21 Apply a light film of oil to the entire Use a horse hairbrush.
350 135-8903 600 ± 30 ml SAE 30 8C-3698
Duo-Cone seal face.
(See Illustration 6) 345B 115-6366 600 ± 30 ml SAE 30 8C-3698
22 Slide shaft and end collar into idler. Use hoist if necessary. 330B 136-2422 A=555 ± 30 ml SAE 30 8C-3698
Shaft
S=625 ± 30 ml
23 Install the o-ring onto the shaft. Duo-Cone
Retainer Seal 142-5491 1000 ml SAE 30 8C-3698
24 From other side of idler, replace the
other end collar on the shaft and 330 102-8152 A=555 ± 30 ml SAE 30 8C-3698
S=625 ± 30 ml

25
press into place.
Use a hydraulic press to reposition Use a hydraulic press for
5 Wipe the seal face using a lint free
6 Apply a thin layer of oil to the entire
325B 115-3696 380 ± 20 ml SAE 30 8C-3698
the bearing blocks. Insert the retaining ring or sledge cloth. 102-8155
seal ring face.
retaining ring or if necessary insert hammer for the pin. Marking 325 102-8155 380 ± 20 ml SAE 30 8C-3698
another pin. "R" and the milled surgace of 322B 115-6337 260 ± 15 ml SAE 30 8C-3698
(See Illustration 7) the shaft face toward the rear 145-7948
of the bearing block when the 322 115-6337 260 ± 15 ml SAE 30 8C-3698
idler is positioned on the
machine. 102-8155 380 ± 20 ml
8E-4007 540 ± 12 ml
26 Check the endplay. See Table 5 for endplay
tolerances. 320S 102-8155 380 ± 20 ml SAE 30 8C-3698
320B 113-2907 180 ± 20 ml SAE 30 8C-3698
115-3696 380 ± 20 ml
320 113-2907 180 ± 20 ml SAE 30 8C-3698
8E-4007 540 ± 12 ml
318B 113-2907 180 ± 20 ml SAE 30 8C-3698
317 113-2907 180 ± 20 ml SAE 30 8C-3698
Press the bearing block into place. 315B 113-2907 180 ± 20 ml SAE 30 8C-3698
315

7 Press the bearing block into place.

313B 114-8257
4I-7337
150 ± 15 ml SAE 30 8C-3698

312B 4I-7337 150 ± 15 ml SAE 30 8C-3698

312 113-2907 180 ± 20 ml SAE 30 8C-3698
4I-7337 150 ± 15 ml

Test and Lubricate 311B, 311

308B
4I-7337
6I-6488
150 ± 15 ml
60 ± 5 ml
SAE 30
SAE 30
8C-3698
8C-3698
307B 145-3017 60 ± 5 ml SAE 30 8C-3698
Step Procedure Reference / Tool Required Critical 6I-6488
27 Lubricate the stopper. Install it Use a light oil to lubricate 307 115-6336 60 ± 5 ml SAE 30 8C-3698
7 ± 7 mm (.3 ± .3 in) below the the stopper. 6I-6488
bottom of the shaft chamfer. 10

0
20 30

50
40 10

0
20 30

50
40

245D 6W-5557 950 ± 25 ml SAE 30 8C-3698

28 Some idlers have a set screw that Use allen wrench. Pressure 245B
O
--M He 8T-0831 Differential
threads into the hub section of the
- Cycleat
Reset
//
Purge

245 3V-4519 950 ± 25 ml SAE 30 8C-3698

idler. Refer to SEBF8495. Gauge
6W-5557
40

50

170-5665
30

29 Use the Test and Fill machine If idler has the threaded plug, QQ 235D 4E-8500 500 ± 25 ml SAE 30 8C-3698
20

(170-5664) to evaluate and fill the use compression fitting with

10

235B
joint. If this is not available, threaded end to form a tight
235C
perform the following test using the seal around the filler nozzle.
40

Refer to SEBF8495. If using 235 2V-8641 500 ± 25 ml SAE 30 8C-3698

50

FT2724. Introduce nitrogen into the

30

lubricant cavity to a pressure of 138 FT2724, do not allow air to Ball Valve 4E-8500
20

110
0
10

kPa (20 psi). Turn the ball valve to enter in a surge and do not
0 220

231D 2V-8641 500 ± 25 ml SAE 30 8C-3698

a shut-off position. Next close the use pressure in excess of 500 ± 25 ml SAE 30
229D 2V-8641 8C-3698
pressure differential gauge. The 138 kPa (20 psi), as this may Pressure Gauge
pressure is to be observed for 10 displace the toric ring. 229
seconds. A pressure drop of 2.5 227 2V-8641 500 ± 25 ml SAE 30 8C-3698
percent (3.5 kPa/0.5 psi) or less is 215C 8V-9106 280 ± 15 ml SAE 30 8C-3698
acceptable.
(See Illustration 8 or 9)
8 Use the Test and Fill Machine
10 Pressure test the roller using FT2724.
215B 8V-9106
3V-5278
280 ± 15 ml SAE 30 8C-3698

30 Add proper oil volume to the idler. See Table 7 for oil fill (170-5664) to evaluate and fill the Introduce nitrogen into the lubricant 6W-7201
volumes. joint. cavity to a pressure of 138 kPa 215 8V-2694 250 ± 50 ml SAE 30 8C-3698
31 Install the plug into the stopper to See Table 4 for proper plug (20 psi). Turn the ball valve to a shut- 8V-9106 280 ± 15 ml
the proper depth. (This step can be depth. off position. Next close the pressure 213B 8R-7396 540 ± 30 ml SAE 30 8C-3698
ignored if idler has a threaded differential gauge. The pressure is to 211B 8R-7396 540 ± 30 ml SAE 30 8C-3698
plug.) be observed for 10 seconds. A
205B 8R-7396 540 ± 30 ml SAE 30 8C-3698
pressure drop of 2.5 percent
32 Tap the end of the idler to check for Use a small hammer.
oil. If there is a dull thud, the idler (3.5 kPa/ 0.5 psi) or less is acceptable. * If your model and roller group are not listed, consult SEBF8576.
contains oil. If there is a ringing
noise, the idler is empty.

RENR0000
Reconditioning
©2002 Caterpillar Inc.
Printed in U.S.A. (6/02)