Use Again

Illustration 51 Measuring for shim pack depth

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Illustration 51 shows measuring for shim pack required to obtain correct bearing preload depending on the application. Refer to the planetary carrier assembly section of the appropriate Disassembly and Assembly manual for shim pack requirements. If the thrust pad has too much wear to meet shim pack requirements, thrust pad cannot be reused. Note: Excessive wear to the bearings or pin shoulder beyond "as new" specifications may also be the cause of failure to meet shim pack requirements.

Thrust Washer Reusability

Planetary carriers using slip fit shafts have thrust washers between the thrust pad and bearing. All current OHT models use plastic thrust washers, however, some machines may still have metal washers in the planetary carriers.

Salvage Procedure
This salvage procedure provides instructions for machining new slots in the thrust washers.
1. Use a glass bead machine to clean the thrust washer of all debris and discoloration thoroughly.

Illustration 5

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Align the slots of the thrust washer.

2. Support the thrust washer on parallel bars. Use a machinist square to align the two existing slots, as shown in Illustration 5. When slots are aligned, clamp the thrust washer in place. 3. Attach a dial indicator to the spindle, and move the table until the thrust washer is centered under the spindle. Use the dial indicator to align (zero) the ID of the thrust washer to within 0.13 mm (0.005 inch) TIR (Total Indicator Runout). See Illustrations 6 and 7.

Illustration 6

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1V-6317 Differential Thrust Washer - centered.

Illustration 7

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Center (zero) the 6G-6523 Final Drive Thrust Washer under the spindle.

4. Remove the dial indicator and insert the appropriate end mill cutter specified in Table 3. Table 3 End Mill and Slot Specifications Part No. 6G-6523 Cutter Size Slot Width Slot Depth

9.53 mm (0.375 inch)

9.53 0.13 mm (0.375 0.005 inch)

12.20 mm (0.480 inch)

1V-6317

6.35 mm (0.250 inch)

6.48 0.13 mm (0.255 0.005 inch)

12.95 mm (0.510 inch)

5. Move the table left or right to position the cutter at the side (edge) of the thrust washer. Move the table until the cutter just contacts the side of the washer. Remove stock to the depth shown in Table 3. See Illustrations 8, 9 and 10.

Tooling Available
Liquid Penetrant

Dye: 4C-4736 Dye (Includes cleaner, dye, and developer) Fluorescent: 4C-4714 Black Light, 4C-4715 Clamping Fixture for Black Light, 4C-4737 Cleaner/ Remover Fluid, 4C-4738 Penetrant, 4C-4739 Developer
Magnetic Particle

Dry powder: 4C-4735 Accessory Kit (Includes magnetic yoke, powder, cleaner) Note: Liquid Magnetic Particle: Not offered by Caterpillar Inc. Use commercially available material. Note: Caterpillar Inc does not offer ultrasonic testing equipment. A specially trained operator is required to use and interpret the ultrasound equipment and data.
Inspection Procedures

Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

To inspect for cracks using the dye penetrant, use the following procedures prepared by the Magnaflux Corporation:

Illustration 14

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1. Preclean inspection area. Spray on cleaner / remover. Wipe off with cloth.

Illustration 15

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2. Apply penetrant. Allow short penetration period.

Illustration 16

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3. Spray cleaner / remover on wiping towel and clean surface clean.

4. Apply a thin film developer. Allow a short developing period. For rough surfaces, daub on a dry developer.

Illustration 23

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5. Inspect under black light. Cracks and lack of bond will show as glowing lines, porosity as spots. To inspect for cracks using the magnetic particle system, use the following procedures prepared by the Magnaflux Corporation:

3. Energize yoke. Magnetic field will form in test place.

Illustration 27

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4. Apply magnetic powder or prepared bath while yoke is energized.

Illustration 28

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5. Indications will appear immediately.

Damage from Foreign Objects

Foreign objects are objects that are not permitted in the drive train. A foreign object will commonly come from the drive train. Under harsh conditions, gear teeth and roller bearings can break. The foreign objects can damage other components in the drive train. Broken teeth from other gears and pieces of failed bearings are the two most common types of foreign objects.

Damage from foreign objects must not penetrate the case hardened surface of a gear. The contact surface of a gear may have only a small amount of damage from foreign objects. Damage from foreign objects must not exist in the fillets on the gear. Damage from foreign objects should not exist on the face of the teeth on a gear. Do not reuse a gear if more than one of the following are true: Significant amounts of damage from foreign objects on a gear Damage from foreign objects will affect the distribution of the load. Damage from foreign objects affects the film of lubrication. Damage from foreign objects exists in the fillet. Damage from foreign objects has penetrated the case hardened surface. Damage from foreign objects is on the threshold of reusing.

Refer to the ""Reconditioning" " section in order to recondition the damage from foreign objects. If the contact surface near the damage will not become stressed under a normal load, the gear may be reused.

Illustration 141

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The illustration shows the typical example of a planetary gear set. Sun gears and planet gears are external gears. Ring gears are internal gears. (35) Ring gears (36) Sun gears (37) Planet gears

1. Correctly locate the carrier onto the fixture for machining. Establish the X and Y axes in relation to the four pin bores (refer to Illustration 7 and Illustration 8).

Illustration 8 Checking the centerline of the bores.

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2. Install a dial indicator into spindle of vertical mill and zero (center) the pin bore. Refer to Illustration 8. a. Place spindle directly in line with one pin bore. a. Position dial indicator into pin bore hole and zero (center) hole to within 0.03 mm (0.001 inch) Total Indicator Reading (TIR). a. Check the centerline of all bores. Make sure that the line of true position is within 0.05 mm (0.002 inch) TIR of the other bores and within 0.10 mm (0.004 inch) of the center bore. 3. After pin bore is centered, lock the vertical and horizontal axes to prevent table movement.

Illustration 9

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Installing the boring bar. Rough and finish machine the pin bore to specified dimensions. Machine counterbore to specified dimensions as shown in Illustration 15 through Illustration 17.

4. Remove the dial indicator and place boring bar into spindle.

Salvage Procedure
1. Thoroughly clean the axle bearing of all debris and discoloration with a solvent. A 8T-7765 Surface Reconditioning Pad may be used to hand polish the part lightly.

Illustration 12

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Typical Example - Bearing is installed in the lathe.

2. Locate the axle bearing in the lathe and indicate (zero) the unworn face to within 0.05 mm (0.002 inch) as shown in Illustration 12.

Note: When locating the bearing in the chuck, care must be taken to use brass or aluminum shims between the inside bore and the chuck jaws to prevent damage to the bore.

Illustration 13

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Typical Example - Machine the damaged thrust surface in order to remove any debris damage and denting.

3. Machine the damaged face to provide complete surface clean-up. Do not remove more than 0.25 to 0.51 mm (0.010 to 0.020 inch) of material from the new specification given in Table 3. See Illustration 13. The machined surface should be given a 1.6 microns (63 microinches) surface finish.

Note: If the gouges are deeper than the specified limits and cover more than 10% of the face, the bearing is not salvageable.

Illustration 14

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Typical Example - ID and OD that have been de-burred.

4. Use a deburr tool to remove any burrs on the Inner Diameter (ID) and the Outer Diameter (OD). 5. Remove the axle bearing from the lathe. Clean the axle bearing in accordance with the section titled ""Cleaning Recommendations" " in this manual. 6. Reassemble the final drive. Refer to the appropriate Disassembly and Assembly manual.
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