RENR3963

Disassembly and Assembly Procedures

for Hydraulic Excavator Rollers
Disassembly

Reconditioning

1. Reference Material
Title

Form Number
Step

Procedure

Reference / Tool Required

Remove plug and stopper, then

drain the oil.

Drill with a .5 inch drill bit.

Remove retaining ring or pin.

Screwdriver or punch.

Remove the end collar.

(See Illustration 1)

Use a hydraulic press.

Remove the o-ring from the shaft.

Rotate roller end for end and slide

the end collar and shaft out of the
roller assembly.

Remove o-rings from end collar.

Remove Duo-Cone seals from end

collars and roller assembly.

Inspect the set of Duo-Cone seals

side by side for reusability.
NOTE: Seals must be kept in
matching pairs if reused.

SEBF8511- proper reuse

information for Duo-Cone
seals.

Measure shaft to bearing clearance.

(See Illustration 2)
NOTE: If one or both bearings fail,
the feeler gauge test use bearing
removal adapter (FT2209 shaft
with FT2210, FT2211 or FT2212
driver) and press to remove both
bearings.

See Table 3 for shaft to

bearing clearance
specifications.

Critical

SEBF8511

Reusability and Assembly Recommendations for Duo-Cone Seals

SEBF8484
SEBF8364
NECG0604
SEBF8574

Tools and Specification Chart for Conventional Duo-Cone Seals

Assembly and Installation of Conventional Duo-Cone Seals
Tool Guide

SEBF8596

Guideline for Reusable Roller and Idler Components

Oil Fill Volume for Rollers

Shaft-to-Bearing
Clearance

2. Tooling Reference

Model Number

Seal Height Tooling

Shaft

3. Shaft/Bearing Clearance

Bearing

Roller

All Models

8T-0450
8T-0447 Calipers

Miscellaneous Tooling
Q

Remove end collar using a hydraulic

press.

Description

Measure shaft-to-bearing clearance.

Tooling Part Number

Plug Installation Tool

5P-7419

Stopper Installation Tool

5P-7392

Bearing Driver Group

1P-0520

Clearance (min/ max)

215B, 219, 219D, 225,

225B, 225D, 227, 229,
229D, 235, 235B, 235C,
231D

0.23 / 0.39 mm
(.00906 / .0154 in)

205, 205B, 211, 211B, 213,

213B, 215B, 215C, 215D,
235C, 235D, 245, 245B,
245D, 320, 320S, 320B,
322, 322B, 325, 325B,
330, 330B, 350, 375

0.25 / 0.48 mm
(.00984 / .0189 in)

231D, 307, 307B, 308B,

312, 312B, 315, 315B, 317,
318, 318B, 320, 320B

0.11 / 0.31 mm
(.00433 / .0122 in)

4. Seal Installers

Preparation for Assembly

Step

Procedure

10

Wash and remove all debris from

roller.
Clean components with alcohol and
dry with a lint free cloth.

11
12

Inspect seals for reusability.

13

Install o-rings in the end collar using

the o-ring compound.

Reference / Tool Required

Model Number

Critical

Use a lint free cloth.

Use 1U-6395 O-ring

compound.

14

Replace toric rings if reusing seals.

15

Dampen toric with proper lubricant.

Use 99% isopropyl alcohol or

approved assembly lubricant.

16

Install seals into end collars and

roller assemblies using the proper
installation tools.
(See Illustration 3)

See Table 2 for installation

tools.

Dry the Duo-Cone seals using

pressurized air at 30 psi for 1
minute.

Not necessary if 99%

isopropyl alcohol is used

Check assembled seal height in

end collars and assemblies at four
locations 90 degrees apart. The
difference in height must not
exceed 1.0 mm (0.039 in).
(See Illustration 4)

See Table 2 for proper seal

height tooling.

17

18

Assembly
Height

Carefully clean shaft without

degrading the seal ramp surface.

Part Number

4C-6206
1U-8849
9U-7537

312, 312 B, 320

1U-6145

307, 307B

123-3800

215B, 219, 219D, 225, 225B,

225D, 227, 229, 229D, 231D,
320B, 320S, 322, 322B,
325B
205, 205B, 211, 215B, 215C,
215D, 312, 312B, 315, 315B,
318B, 320, 320B, 325

1U-8842

235D, 245, 245B, 245D

1U-6443

227, 231D, 235, 235D, 245

215B, 225

Procedure

19

Lightly lubricate the bearings with

the same oil type used to fill the
roller.
Wipe the entire Duo-Cone seal ring
face in end collars and roller
assemblies.
(See Illustration 5)

20

21

Apply a light film of oil to the entire

Duo-Cone seal face.
(See Illustration 6)

22

Slide shaft and end collar into roller.

23

Install the o-ring onto the shaft.

24

Rotate the roller end for end and

place the other end collar on the
shaft and press into place.

25

26

Install Duo-Cone seals into end

collars and roller assemblies using
the proper installation tool. Use a
sudden, even, perpendicular force to
install the seals.

Check assembled seal height in the

retainer at 4 locations 90 degrees
apart.

Model Number

All Models

Reference / Tool Required

Critical

Seal Face
That Gets
Oiled

Use hoist if necessary.

307, 307B

3P-4603

7. Stopper Part Numbers

Tolerance (min/ max)

0.25 / 1.25 mm
(.009843 / .04921 in)

Model Usage

Part Number

205, 205B, 211, 211B, 213,

213B, 215B, 215C, 215D,
231D, 312, 312B, 315, 317,
318, 318B, 320, 320S, 320B,
322, 322B, 325, 325B, 330,
330B, 350, 375

5P-2247

Check the endplay.

See Table 6 for endplay

tolerances.

385, 375

185-5065
185-5102
176-8620
176-8621
152-4129
152-4134

1055 55 ml

SAE 30

8C-3698

745 35 ml

SAE 30

8C-3698

330

5Q-3206
179-1486
179-1491

460 25 ml
437 25 ml

SAE 30

8C-3698

330B

179-1486
183-2874
5Q-3203
179-4147
179-4148

437 25 ml

SAE 30

8C-3698

A= 285 15 ml
M= 350 15 ml

SAE 30

8C-3698

A= 285 15 ml
M= 350 15 ml

SAE 30

8C-3698

280 15 ml
350 15 ml

SAE 30

8C-3698

255 10 ml

SAE 30

8C-3698

255 10 ml

SAE 30

8C-3698

350

Duo Cone
Retainer Seal

Wipe the seal face using a lint free

cloth.

325

325B

Apply a thin layer of oil to the entire

seal ring face.
322, 322B

Press the bearing block into place.

8C-3698

312B, 312

5Q-3220
151-9747
127-3806

150 ml

SAE 30

8C-3698

70 5 ml
70 5 ml
145 15 ml
1600 50 ml

SAE 30
SAE 30

8C-3698
8C-3698

SAE 30

8C-3698

420 30 ml

SAE 30

8C-3698

340 25 ml
420 30 ml
450 15 ml

SAE 30

8C-3698

235C

Critical

Use a light oil to lubricate

the stopper.
20

20

30

40

10

See Table 2 for plug

installation tool.

31

Tap the end of the roller to check

for oil. If there is a dull thud, the
roller contains oil. If there is a
ringing noise, the roller is empty.

Use a small hammer.

40

Install the plug into the stopper to

the proper depth of 0 + 2 mm.

50

30

See Table 8 for oil fill

volumes.

170-5665

30

Add proper oil volume to the roller.

Purge

20

29

Pressure
Differential
Gauge

8T-0831

He
Cycleat
Reset
//

9W-5586

450 15 ml

SAE 30

8C-3698

231D, 229D,
227
225

8E-4576

340 25 ml

SAE 30

8C-3698

8E-4579

420 30 ml

SAE 30

225B, 225D
219, 219D

8E-4573

320 20 ml

SAE 30

8C-3698
8C-3698

215C, 215D,
213, 213B, 211,
211B, 205,
205B

8E-7494

350 20 ml

SAE 30

8C-3698

50

QQ
O
--M
-

235D

40

10

If using FT2724, do not allow

air to enter in a surge and do
not use pressure in excess of
138 kPa (20 psi), as this may
displace the toric ring.

30

10

127-3806
127-3807
8E-0830
8E-0831
8E-4579
124-8250
134-6636
8E-4576
8E-4579
9W-5586

30

50

40

Use the Test and Fill machine

(170-5664) to evaluate and fill the
joint. If this is not available,
perform the following test using the
FT2724. Introduce nitrogen into the
lubricant cavity to a pressure of 138
kPa (20 psi). Turn the ball valve to
a shut-off position. Next close the
pressure differential gauge. The
pressure is to be observed for 10
seconds. A pressure drop of 2.5
percent (3.5 kPa/0.5 psi) or less is
acceptable.
(See Illustration 8 or 9)

50

350 15 ml
SAE 30

235B, 235

Reference / Tool Required

CAT Part Number

225 10 ml

245D, 245B,
245

Test and Lubricate

Oil Weight

163-4143

307B, 307

Press the end collar into place.

5Q-3203
152-4125
163-4147
163-4145
152-4125
163-4147
163-4143
163-4144
163-4143
163-4144
163-4147

Oil Volume (ml)

318B, 317,
315, 315B

308B

Ball Valve

20

* If your model and roller group are not listed, consult SEBF8574.

110

10

28

1U-8843

Roller Group

Shaft

Use a hydraulic press.

Use a hydraulic press.

Lubricate the stopper. Install it

7 7 mm (.3 .3 in) below the
bottom of the shaft chamfer.

9W-2146

1U-8840

205, 205B, 211, 211B, 213,

213B, 215B, 215C, 215D,
219, 219D, 225, 225B,
225D, 227,229, 229D,
231D, 235, 235B, 235C,
235D, 245, 245B, 245D

Model Number

320B

27

6Y-0473

8. HE Oil Fill Volumes

Insert the retaining ring or if

necessary insert another pin.
(See Illustration 7)

Procedure

205, 205B, 211, 211B, 213,

213B, 215B, 215C, 215D,
231D, 312, 312B, 315,
315B, 317, 318, 318B, 320,
320S, 320B, 322, 322B,
325, 325B, 330, 330B, 350,
375

6. Endplay Tolerances

Part Number

Check assembled seal height in the

retainer at 4 locations 90 degrees
apart.

320

Step

Model Usage

1U-8841

Assembly
Step

5. Plug Part Numbers

375
350
330, 330B

220

Pressure Gauge

Use the Test and Fill Machine

(170-5664) to evaluate and fill the
joint.

10

Pressure test the roller using FT2724.

Introduce nitrogen into the lubricant
cavity to a pressure of 138 kPa
(20 psi). Turn the ball valve to a shutoff position. Next close the pressure
differential gauge. The pressure is to
be observed for 10 seconds. A
pressure drop of 2.5 percent
(3.5 kPa/ 0.5 psi) or less is acceptable.

RENR3963
Reconditioning
2002 Caterpillar Inc.
Printed in U.S.A. (6/02)