COVER 4530861 - Caterpillar

Assembly Procedure
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
(A)     1U-6443     Seal Installer     1    
(B)     8T-5096     Dial Indicator Test Group     1    
Thoroughly clean all of the parts of the front idler prior to assembly. The weight of the front idler is 245 kg (540 lb).
Illustration 1 g00494553
Check the condition of bushings (7). If the bushings are worn or damaged, use new parts for replacement.
Lower the temperature of bushings (7), and install one in each side of the front idler with a press.
Illustration 2 g00494532
Illustration 3 g00483283
Temporarily install a bearing (2) on shaft (5) .
Install the shaft in the front idler. Install the other bearing (2) on the shaft.
Use Tooling (B) to check the end play of the shaft. The shaft end play must be 0.26 mm (.010 inch) to 1.26 mm (.050 inch).
Remove two bearings (2) and shaft (5) from the front idler.
Illustration 4 g00494560
Illustration 5 g00494583
Note: The rubber seals and all of the surfaces that make contact with the seals must be clean and dry. After the installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals. Note: For more information concerning the assembly and installation of Conventional Duo-Cone seal kits, refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.
Install a duo-cone seal kit (6) in each side of the idler with Tooling (A) .
Install a Duo-cone seal kit (3) in each bearing (2) with Tooling (A) .
Illustration 6 g00494546
Check the condition of O-ring seals (4) that are used on shaft (5). If the O-ring seals are damaged, use new parts for replacement.
Install two O-ring seals (4) on shaft (5). Put clean SAE 30 oil on the O-ring seals.
Illustration 7 g00494526
Check the condition of spring pins (1) that are used to hold bearings (2) to shaft (5). If the spring pins are worn or damaged, use new parts for replacement.
Illustration 8 g00494586
Install shaft (5) in either bearing (2). Make sure that the spring pin hole in the shaft is aligned with the spring pin hole in the bearing. Also, make sure that the marking "R" and the milled surface of the shaft are facing toward the rear of the bearing when the bearing is positioned on the machine.Note: Do not reuse spring pin (1). Use a new part for replacement.
Install a new spring pin (1) in order to hold the unit together. Position the slit in the spring pin, as shown. Refer to Illustration 8.
Install the shaft and the bearing in the front idler.
Repeat Step 13 in order to install the other bearing (2) on shaft (5) .
Be sure that the spring pin hole in the shaft is aligned with the spring pin hole in the bearing.Note: Do not reuse spring pin (1). Use a new part for replacement.
Install spring pin (1) .
Check the front idler for air leaks. Apply 245 kPa (35.5 psi) to 265 kPa (38.5 psi) of air pressure to the idler.