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Product: MOTOR GRADER
Model: 120K MOTOR GRADER SZN
Configuration: 120K Motor Grader SZN00001-UP (MACHINE) POWERED BY C7 Engine
i07386203
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Introduction
Table 1
Revision Summary of Changes in SEBF8193
Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018.
21
Removed Repair Process Engineering (RPE) old point of contacts.
New Repair Process Engineering (RPE) point of contact added.
20 Added extra photos.
19 Added extra photos.
18 Added Expanded Mining Products and extra photos.
© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein
without permission may be violation of intellectual property law.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage informationr462het
Caterpillar:
enables Cat dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known Confidential Yellow
to Caterpillar.
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Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and
Salvage Guideline must be used with the latest technical information that is available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web)
Interface.
Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident
can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the
product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible
circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a
tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are
used.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you
or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The “WARNING” safety alert symbol
is shown below.
Illustration 2 g00008666
Pay attention!
Become alert!
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. r462het
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Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety
information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that
the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication,
maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The
specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is
given to the product. Obtain the complete, most current information before you start any job. Cat dealers can supply the most current information.
Summary
This guideline contains information which can help to determine visually the reusability of gears in the drive train. This guideline also contains the operational
characteristics of gears in the drive train. The information that is shown in this guideline will help to explain the cause and succession of a failure. Never install a
part that is shown in this guideline as a part that cannot be used again. This guideline can help to identify the gears that may be used again by illustrating the typical
modes of failure. This guideline cannot guarantee that any individual gear can be reused. There is always some risk of failure. Experience and careful inspection is
the best guideline for proper usage of gears.
NOTICE
References
Use the following references for additional information regarding the rebuild of a drive train.
Table 2
References
SEBF8029 Reuse And Salvage Guidelines "Index of Repair Process Engineering Publications"
SEBF8148 Reuse And Salvage Guidelines "General Salvage and Reconditioning Techniques"
SEBF8185 Reuse And Salvage Guidelines "Salvage Procedure for Final Drive Planet Gear Used in Off-Highway Trucks"
SEBF8187 Reuse And Salvage Guidelines "Standardized Parts Marking Procedures"
NOTICE
Table 3 contains the items that are needed to complete the repair procedures in this guideline.
Table 3
Tooling and Equipment
Part Number Description
1U-9918 Wire Brush
1P-3537 Dial Bore Gauge Kit
4C-4804 Penetrant
4C-4805 Developer r462het
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Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
• Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and oil.
• When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator,
all lifting devices must be inspected before use.
• If the bore cannot be inspected immediately after cleaning, put hydraulic oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in
a clean container.
The code is a Caterpillar standard. The code is used to record the history of a gear. The code will identify the number of rebuilds and hours at the time of each
rebuild. This information is important for any decision to reuse a gear. The information should be considered for making an informed decision to reuse a gear. The
information should be considered for locating the cause of a failure.
The mark should be on the sides of planetary gears and sun gears. The mark is not to be covered by a mating part. Use 9U-7377 Metal Marking Pen that is listed in
"Tooling and Equipment" to mark the code onto the gear.
The procedure for marking gears is a Caterpillar standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an
overhaul, the previous code of a part should never be removed.
NOTICE
Do not use a numbering stamp punches set to mark internal parts. The
impact from striking the stamp will cause an abnormal stress riser.
The added stress riser may cause the part to fail prematurely.
Example 1
Illustration 3 g03885120
Illustration 3 shows code (1-15). The first number (1) indicates that the component had been rebuilt once. The second number (15) indicates that there were 15,000
hours on the gear at the time of rebuild.
Example 2
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Illustration 4 g03885129
Illustration 4 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the component
had been rebuilt twice. The second number (10) indicates that there were 10,000 hours on the gear at the time of rebuild.
Note: To obtain the total number of hours for the component in Illustration 4, add first and second rebuild hours. In this example the component has a total of
22,000 hours.
Table 4
Crack Inspection Method Advantages vs. Disadvantages
Inspection Method Advantages Disadvantages
- Least expensive
- Limited to surface-only defects
Visual Surface Inspection - Detects most damaging defects
- Requires inspectors to have broad knowledge of welding and fabrication in
(VT) - Immediate results
addition to NDT
- Minimum part preparation
- Inexpensive
- Least sensitive
- Minimal training
Liquid Penetrant (PT) - Detects surface cracks only
- Portable
- Rough or porous surfaces interfere with test
- Works on nonmagnetic material
- Portable
Dry Magnetic Particle - Works on magnetic material only
- Fast/Immediate Results
(MPT) - Less sensitive than Wet Magnetic Particle
- Detects surface and subsurface discontinuities
- More sensitive than Liquid Penetrant - Requires Power for Light
Wet Magnetic Particle
- Detects subsurface as much as 0.13 mm - Works on magnetic parts only
(MPT)
(0.005 inch) - Liquid composition and agitation must be monitored
- Most sensitive
- Detects deep material defects - Most expensive
Ultrasonic Testing (UT) - Immediate results - Requires operator training and certification
- Wide range of materials and thickness can be - Surface must be accessible to probe
inspected
- Difficult to interpret
- Surface and near surface flaws detectable
- Only for metals
Eddy Current Testing (ET) -Moderate speed/Immediate results
-Rough surfaces interfere with test
-Sensitive too small discontinuities
- Surface must be accessible to probe
-Detects surface and internal flaws - Not for porous materials
Radiographic Testing (RT) - Minimum part preparation - Radiation protection needed
- Can inspect hidden areas - Defect able to be detected is limited to 2% of thickness
Table 5
Applicable Crack Detection Standards
Required
Acceptance r462het
Type Standard Personnel
Criteria Caterpillar: Confidential Yellow
Qualifications
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Visual Surface Inspection (VT) EN-ISO 5817 EN-ISO 5817 - Level B EN-ISO 9712 - Level 2
AWS D1.1 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 3452 EN-ISO 23277 EN-ISO 9712 - Level 2
Liquid Penetrant Testing (PT)
ASTM E165 AWS - D1.1 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 17638 EN-ISO 23278 - Level 1 EN-ISO 9712 - Level 2
Magnetic Particle Testing (MPT)
ASTM E709 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 17640 - Level B EN-ISO 11666 Technique 2 - Level 2 EN-ISO 9712 - Level 2
Ultrasonic Testing (UT)
AWS D1.1 AWS D1.1 - Class A - Table 6.3 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 15549 EN-ISO 9712 - Level 2
Eddy Current Testing (ET) EN-ISO 20807
ASTM E426 ANSI-ASNT SNT-TC-1A Level 2
EN-ISO 5579 EN-ISO 9712 - Level 2
Radiographic Testing (RT) EN-ISO 10657-1
ASTM E94 ANSI-ASNT SNT-TC-1A Level 2
NOTICE
Illustration 5 g06085008
Example of Visual Inspection Tools
(A) Flashlight or adequate light source
(B) Magnifying eye loupe
(C) Tape measure or other measuring device
(D) Inspection mirror
(E) Weld size inspection gauges
Components and welds that are to be inspected using PT, MPT, or UT shall first be subject to visual inspection (VT). Visual Inspection is often the most cost-
effective inspection method and requires little equipment as seen in Illustration 5. It is suggested that at a minimum personnel performing Visual Inspection are
either trained to a company standard or have sufficient experience and knowledge about the components being inspected. It is also suggested that personnel
performing visual inspections take some type of eyesight test regularly.
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
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that is used.
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• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.
• Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.
• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the
penetrant indications.
• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
Illustration 6 g06087907
Typical example of checking for cracks in the welded areas.
1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent dampened cloth to remove
remaining dirt and allow the area to dry. If, there is a visible crack remove paint using paint remover or wire brush.
Illustration 7 g06087912
Typical example of checking for cracks in the welded areas.
2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been allowed to soak,
remove the excess penetrant with clean, dry wipe.
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Illustration 8 g06087914
3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
Illustration 9 g06087916
4. Before using Developer, ensure that the developer is mixed thoroughly by shaking can. Hold thecan approximately 8-12 inches away from part, apply an
even, thin layer of developer over the area being inspected. A few thin layers are a better application method than one thick layer.
Illustration 10 g06084042
Typical example of cracks found during a liquid penetrant examination.
5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to
Illustration 10. Clean the area of application of the developer with solvent cleaner.
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Illustration 11 g06085930
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(C) Dry powder bulb.
1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder
shall be of a color that will provide adequate contrast with the background of the surface being inspected.
2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and
excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine
further use of the powder.
3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.
4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This
coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the
electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).
5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have
sufficient force to remove excess particles without disturbing those particles that are evidence of indications.
6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.
Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.
2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.
3. Simultaneously apply the dry powder using the dry powder blower.
5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the
magnetic field are created.
6. Observe particles and note if any clusters of particles appear revealing an indication.
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Illustration 12 g06085937
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(D) UV Lamp used in wet magnetic particle inspection process.
Illustration 13 g06003178
Pear Shaped Centrifuge Tube
1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.
2. Concentration:
a. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.
b. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with
0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 13. Before sampling, the suspension shall be thoroughly mixed to assure
suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes.
The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.
c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
◾ Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.
e. The conditioning agents used in the conditioned water shall have the following characteristics:
◾ Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C (100° F).
3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This
coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the r462het
electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of Caterpillar:
at least 4.5 Confidential
kg (10 lbs).Yellow
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Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.
2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
Illustration 14 g03536210
◦ Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the
magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized,
the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 14 for an example of yoke
placement.
NOTICE
1. Ultrasonic testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz)
to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object
being inspected.
2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.
a. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being
tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect from the back surface of
the material to project the thickness of the material.
b. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after
traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence
of the imperfections.
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Illustration 15 g06090873
Eddy-current testing
NOTICE
Eddy-current testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow is induced in the test object. Changes in the flow caused by
variations in the specimen are reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and techniques. Major applications of eddy-
current testing are surface inspection and tubing inspections.
Radiographic Testing
Illustration 16 g06090892
Radiographic Testing
All personnel involved in radiographic examinations shall be qualified to Level 2 in accordance to standards stated in Table 5.
Illustration 17 g00008666
This process is dangerous. Only qualified personnel and test equipment should be appointed to perform this type of testing.
Radiographic testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength of electromagnetic radiation is used to penetrate materials to find
hidden discontinuities such as cracks. In radiographic testing, the test object is placed between the radiation source and the film, or x-ray detector. The
electromagnetic radiation will penetrate the thickness of the test object and, when all the way through, will project onto the film any indications that have been in
the path of the radiation waves.
Nomenclature of Gears
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Illustration 18 g03885136
Key elements of a gear are identified in Table 6.
Table 6
Nomenclature of Gear Teeth
Item Description
1 End
2 Tip
3 Land of tip
4 Edge
5 Face of tooth
6 Highest point of single tooth contact (HPSTC)
7 Pitch Line
8 Lowest point of single tooth contact (LPSTC)
9 Fillet
10 Root
11 Start of active profile
12 Crown
13 Profile
14 Pitch diameter of gear
15 Thrust face
Glossary of Terms
Profile - The profile of the gear teeth is the shape or the outline of the gear tooth from the side of the gear.
Addendum - The addendum is the section of tooth that is above the pitch line.
Pitch Line - The pitch line is located between the highest point of single tooth contact (HPSTC) and the lowest point of single tooth contact (LPSTC). Sliding
between the surfaces of gear teeth does not occur at the pitch line. r462het
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Crown - The crown of a gear tooth is the outline that can be seen from the top of the tooth. The crown is shown as item (12) in Illustration 18. The roundness of the
crown of a tooth compensates for a minor misalignment between the teeth of a gear. The crown can also help distribute the load from the center of the tooth
outward for more efficiency.
Dedendum - The Dedendum is the section of the gear tooth that is below the pitch line.
DO NOT USE THIS PART AGAIN - The DO NOT USE THIS PART AGAIN refers to a part that is either out of specifications or is damaged upon repair and is
not to be used again.
USE THIS PART AGAIN - The USE THIS PART AGAIN refers to a part that after accurate inspection and reconditioning, has meet the criteria and can be used
again.
BORDERLINE - BORDERLINE refers to a part that depending on the application, operation, maintenance, and serviceability should be considered reusable or
not. Use proper inspection procedures to verify.
Gear Types
Illustration 19 g03885141
Spur Gears
Spur gears have parallel shafts. The load is applied to one single tooth. The load is applied to 1/3 of the adjacent tooth.
Illustration 20 g03885145
Helical Gears
Helical gears have either parallel shafts or perpendicular shafts. Helical gears are quiet. Multiple teeth carry the load.
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Illustration 21 g03885152
Straight Bevel Gears
Straight bevel gears have either angled shafts or perpendicular shafts. Approximately 1 and 1/3 teeth carry the load. Some end thrust is produced.
Illustration 22 g03885159
Spiral Gear
Hypoid pinions or spiral gear shafts are perpendicular to each other. The gear teeth are curved to provide more contact area between mating teeth. The design creates quiet operation with more
sliding tooth contact, and end thrust. Two or more teeth carry the load.
There are several different case hardening heat treatments. The most typical treatments for Caterpillar gears are nitriding and carburizing. Nitriding provides a
shallower hardened case typically from 0.13 mm (0.005 inch) to 0.3 mm (0.01 inch). Nitrided gears, which require higher dimensional accuracy, are loaded with
lighter loads. Carburized gears are typically utilized in applications with the highest loads. The carburized gears are typically used in final drives. The depths of the
case can vary from 0.5 mm (0.02 inch) to 2.0 mm (0.08 inch).
The proper selection of design, materials, and heat treatment produce gears that are capable of providing the best life and performance in the harshest applications.
• Machine application
• Machine operation
• Machine maintenance
Assume high hours, insufficient maintenance, and heavy applications if the history of the machine is not known. Decisions for reusing gears should never be
based on one characteristic. Gears are designed to withstand the sliding action between the surfaces of mating teeth. Gears are not designed to withstand conditions
of insufficient lubrication. Insufficient lubrication can cause direct contact between gears. Direct contact increases resistance and operating temperatures.
Inadequate lubrication will cause serious damage if regular maintenance is ignored. These conditions will eventually contribute to abnormal wear or accelerated
wear during operation.
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1. Gear trains are easily contaminated during field assembly. Always use clean procedures. Clean procedures will always minimize the possibility for
contamination.
2. Use only the recommended procedures for assembly. Proper levels of oil should be maintained. Only use Caterpillar recommended lubricants to minimize
internally generated debris from wear.
4. Schedule a Scheduled Oil Service (SOS) that is certified by Caterpillar to find possible causes of oil contamination. An oil analysis can help determine the
cause of a failure. An oil analysis can also help the prevention of possible future failures. Keep an accurate record of the machine hours and application. The
information will be used during the oil analysis to generate the most accurate diagnosis.
5. The specified filters should be used and changed at the recommended intervals if gear oil passes through a system of filters.
6. Change the drive train oils at the recommended intervals. The intervals can be found in the Service Manual for the machine.
7. Be certain that all gears are free of rust and debris during a rebuild. Examine the gears to check for any damage from handling.
Illustration 23 g03880743
Do not place gears on the floor or stack the gears on top of each other.
8. Gears should be handled carefully. Gears should be stored properly during rebuilding. Gears are easily chipped. A chipped tooth is shown in Illustration 24.
a. Do not stack the gears or place the gears on the floor. Illustration 23 shows the improper way of stacking gears.
b. Stack the gears in a stable pattern. Place the large gears on the bottom and the smaller gears toward the top. Use cardboard to separate the gears when
gears are stacked.
c. Use a nylon sling to lift a gear. Use of a nylon sling will help to prevent damage to the bore of the gear. Follow all Caterpillar safety standards for
operating a hoist.
9. Record the history of the machine. Record the hours of usage for the component.
Illustration 24 g03885167
Not properly handling a gear may cause the teeth to break. The gear in the above illustration was not handled properly.
10. Record the number of rebuilds and hours on all gears. Refer to "Standardized Parts Marking Procedure" for more information.
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Caterpillar gears deliver maximum performance and productivity under extreme loads. The teeth of the gears move against each other. The teeth are under high
stress to convert engine horsepower into torque. Caterpillar gears in drive trains are built with the purpose of transmitting extreme loads. The gears are built to work
as a system with the following unique features:
The properties of Caterpillar gears differentiate the gears from other replacement or remanufactured gears. Maximum machine performance and productivity can be
ensured by installing genuine Caterpillar gears in your Caterpillar equipment. Caterpillar gear teeth are specially shaped to distribute stress over a large area. The
shape of the gears prevents tooth fracture.
Competitive Gears
Competitive manufacturers of gears claim to produce gears that can be used in many different machines because the gears are designed for multiple pieces of
equipment. Every Caterpillar gear has a specific design for each application. These acute yet important differences are critical to the life of any drive train. The use
of Caterpillar gears will ensure correct gear tooth contact and efficient power flow under varying load conditions. Only Caterpillar genuine gears should be
installed into Caterpillar equipment.
Metallurgy
Caterpillar gears have unique metallurgical compositions. The metallurgical content of each gear is tailored to the specific application of the gear. Caterpillar
improves the impact resistance of the gears. Caterpillar also ensures the proper transfer of loads and consistency by utilizing special steel formulas.
Highly loaded gears in the drive train require a case hardened surface. All gears in the drive train are heat treated to a specified level of hardness. The depth of the
case hardened surface depends on the size of the gear, the application of the gear, and the metallurgy of the gear. The Caterpillar patented heat treat process can
offer extended gear life to highly loaded gears in drive trains. The smallest Caterpillar gears will usually be heat treated to a depth of at least 0.20 mm (0.008 inch).
Large Caterpillar gears can be heat treated to a depth of 12.70 mm (0.500 inch).
The gear teeth go through a combined rolling and sliding action when gears rotate in and out of a mesh. Rolling and sliding occurs during contact above the pitch
line and below the pitch line. Only rolling occurs at the pitch line.
Illustration 25 g03885179
The illustration shows the rolling and sliding action that occurs as a gear rotates.
(14) Pitch diameter
(16) Loaded side of tooth
(17) Unloaded side of tooth
(18) Rolling action
(19) Rolling and sliding action
The LPSTC is low on the gear tooth. Pitting usually occurs at the LPSTC. The HPSTC is high on the gear tooth. Scoring usually occurs at the HPSTC and above r462het
the HPSTC. Caterpillar: Confidential Yellow
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Illustration 26 g03885181
LPSTC and HPSTC
(6) HPSTC
(8) LPSTC
(20) Driven gear
(21) Driving gear
(22) Full tooth contact with rolling action
The load on gear teeth and the velocity of gear tooth contact relate to each other. Wear increases with increases in load. Scoring increases with increases in the
velocity of contact.
Illustration 27 g03885185
Gears have maximum operating life in zone (24). The oil must be clean. Maximum life of the gear will occur under medium gear speeds. Maximum life of a gear will occur under lower loads on
gears. The line of wear (23) will increase at a steeper angle if the oil is contaminated. Oil contamination will shift the complete graph toward the origin.
(23) Wear
(24) No wear with clean oil
(25) Scoring
(26) Pitting
(27) Breakage
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(28) Velocity of contact Caterpillar: Confidential Yellow
(29) Load
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Thickness of Lubrication
The thickness of the lubrication film is important. The temperature of the lubrication, the amount of the lubrication, and speed of the gear can affect the thickness of
the lubrication. The thickness of lubrication can also affect the type of wear. Refer to Illustration 27 for the following combinations of the usage of gears.
Slow gear speed - A slow gear speed can allow the oil to leave the surface of the gear. Slow gear speeds can cause metal contact. At a slow gear speed, the gear
teeth will have insufficient lubrication.
Fast gear speed - A fast gear speed can cause the teeth to penetrate the thin film of lubrication during operation. Gear speeds that are too fast usually result in
metal tooth contact.
High loads on gears - A high load at a slow velocity of gear contact will have accelerated wear characteristics . High loads can penetrate a thin film of lubrication.
A high load can break the film of lubrication at both slow gear speeds and fast gear speeds. Accelerated wear can happen at slow speeds. Breakage and pitting may
happen at high gear speeds.
High velocity of gear contact - High velocities of gear contact will usually cause scoring. High velocities of contact with elevated loads will usually cause pitting.
Inspection Procedure
Accurate inspection is an important necessity for the life of any gear. The maximum life of any drive train can be obtained through proper inspection and repair
procedures. Refer to "Tooling and Equipment" for a list of tooling for inspection. When you examine a gear, always use good lighting. If an unacceptable gear is
reused, it is possible that the gear will fail. The gear that failed will destroy other components in the drive train. The technician that is performing the inspection
should be familiar with all types of gear wear and damage. The most common reasons for gear failure are described in this Guideline. Decisions on reusing gears
are helped by close inspections.
Illustration 28 g03880745
Use a clean, white piece of paper with a dull finish to reflect light onto the face of each gear tooth during the inspection process.
Use the following tools to identify damaged areas during the inspection process:
• Magnifying glass
• White paper
Refer to Reuse And Salvage Guidelines, SEBF8148, "General Salvage and Reconditioning Techniques" for detailed information on inspection.
1. Clean all gears thoroughly before inspecting the gears. Refer to "Prepare the Area for Inspection"
2. Inspect the entire surface area of the gear for the following damage:
◦ Pitting
◦ Spalling
◦ Cracking
3. Carefully inspect the bore of the gear with a bright light. Bearing bores for planetary gears can be sensitive to high loads and speeds. Careful inspection for
damage is critical.
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a. Rim of gear
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b. Spline
c. Bearing surface
Illustration 29 g03880746
Notice the white plastic on top of the bench. It is easy to clean the surface. The surface reflects light. Also, the surface will not damage the gears on contact.
5. Use Table 7 to ensure that the gear is inspected for all possible damage.
Table 7
Checklist for Inspecting Gears
Item Yes No
Normal wear
White layer flaking
Wear from high hour
Abnormal wear
Frosting
Pitting
Initial
Corrosive
Destructive
Spalling
Pitting or spalling
Scoring
Case crushing
Corrosion or corrosive pitting
Abrasive wear
Nicks
Cracks
Chipping
Uneven contact
Damage from foreign object
Rippling or Lipping
Bores in gears
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Bores in planetary gears Caterpillar: Confidential Yellow
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Reconditioning
Gears with limited damage on the surface may be used again after the damaged area has been polished with 6V-2010 Polishing Stone and oil. Caterpillar
recommends the use of a polishing stone and oil. Never use a die grinder to recondition a gear. A die grinder can remove the case hardened surface of a gear. Refer
to Illustration 31.
NOTICE
If the tooth has a raised metal area, remove only the raised portion on
the tooth surface. Do not try to remove pitting or any other recessed
surface damage. Do not use a grinder or power polisher, use only a
hand-held stone. Using power tools to remove damage can also remove
the case hardened surface of the gear, causing eventual failure.
Illustration 30 g03885189
6V-2010 Polishing Stone and oil should be used to polish a tooth. Be aware of the adjacent tooth. The corner of the stone can easily damage adjacent teeth.
Illustration 31 g03885193
A grinder had been used on this gear in an attempt to recondition the teeth. Use 6V-2010 Polishing Stone and oil for reconditioning the teeth on a gear. Do not use a grinder. The grinding process
can remove the case hardened surface of a gear.
DO NOT USE THIS PART AGAIN.
Machining
This section covers the basic stages that are required to machine a gear.
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Illustration 32 g03885198
The horizontal marks were created during the manufacturing process. These marks are rough machining marks. The marks are not really cracks. Use one of the inspection methods to make sure
that the marks are not cracks.
USE THIS PART AGAIN.
Illustration 33 g03885204
The burrs that are on the gear are not lipping. The machining process can leave burrs on the edges of gear teeth. Dull cutting tools can cause burrs.
USE THIS PART AGAIN.
Rough Machining
The gear teeth are often machined by using a hob process. If a gear has been through a hob process, it is easy to notice the rough machining marks on the surfaces
of the teeth and the burrs on the edges of the teeth .
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Illustration 34 g03885207
This gear has been through the rough machining process. A hob tool was used in this process.
Illustration 35 g03885209
The marks from the hob (1) are visible on the face of the tooth on the gear in the image. The rough machining marks and burrs that are left from the hob process will be removed during the final
machining process.
Finish Machining
A machining process is used after the gear teeth have been cut with the hob process. This process is called shaving. Illustration 36 shows the appearance of a new
gear that has passed through the process of shaving. This gear is ready for heat treatment.
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Illustration 36 g03885212
The image shows a new gear that has not been through the heat treat process. The marks from shaving (2) that are shown in Illustration 36 will be visible after many of hours of use. These marks
are positioned on the face of the tooth at a slight angle.
The area of the root fillet is not a contact surface so the area of the root fillet does not need the final machining process. The marks from the hob (1) will be left in the root fillet. This gear is ready
for heat treatment.
Illustration 37 g03885213
The marks from shaving (2) and the marks from the hob (1) are more visible in the magnification of Illustration 36.
Illustration 38 g03885215
The wear pattern of the gear that is shown in the illustration is an ideal wear pattern. The pattern of wear is centered and even on the tooth. During operation of the gear train, the marks from
shaving will slowly wear away. Notice that the contact ends before reaching the tip of the gear tooth. The gear teeth are designed to reduce the occurrence of chipping at the edges and scoring at
the tips.
USE THIS PART AGAIN.
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Illustration 39 g03885217
The image shows marks from the hob (1). Inspect the gear for cracks with any of the methods for inspecting cracks.
USE THIS PART AGAIN.
Illustration 40 g03885218
A machining mark may look like a crack. Inspect the gear with any of the methods for inspecting cracks if the gear appears to have a crack. Machining marks should not appear while detecting
cracks. The machining marks are not commonly deep. Normal wear will smooth the surfaces and normal wear should be evenly distributed across the teeth.
USE THIS PART AGAIN.
Normal Wear
This section will describe the types of normal wear patterns that can develop by a gear. Normal gears consist of white layer flaking, and wear from high hours.
Usually, gears that only have normal wear can be used again.
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Normal wear is shown in this illustration. The machining marks are shown by the arrows. The machining marks are still visible on this gear.
USE THIS PART AGAIN.
Illustration 42 g03886510
Tooth wear is shown in this illustration. Wear pattern is reasonably centered. Wear is through all machining marks, but does not appear excessive.
USE THIS PART AGAIN.
Illustration 43 g03886515
Tooth wear pattern is shown in this illustration. Well-defined contact edge.
USE THIS PART AGAIN.
Illustration 44 g03886717
Tooth wear pattern is shown in this illustration. Pattern appears normal.
USE THIS PART AGAIN.
r462het
Caterpillar: Confidential Yellow
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Illustration 45 g03886721
High tooth wear pattern is shown in this illustration. Pattern appears normal.
USE THIS PART AGAIN.
Illustration 46 g03886939
Tooth wear pattern is shown in this illustration. Wear pattern appears normal.
USE THIS PART AGAIN.
Illustration 47 g03886948
The illustration shows tooth wear pattern. Wear pattern appears normal.
USE THIS PART AGAIN.
Gears that are hardened by nitride develop a thin brittle skin (2) that may flake off during normal operation. White layer flaking is a normal type of gear wear. Most
gears that show signs of white layer flaking can be used again.
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Illustration 48 g03885226
White layer flaking (1) is shown. The flaking of the skin appears to be destructive, but the flaking is not destructive. The gear may be reused.
USE THIS PART AGAIN.
Illustration 49 g03885230
The image is a magnified view of the thin brittle skin (2) that can develop on gears that are hardened by nitride.
USE THIS PART AGAIN.
Illustration 50 g03885233
The rough machining marks have caused the load to become concentrated in certain areas. The pattern of the white layer flaking follows the machining marks.
USE THIS PART AGAIN.
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Illustration 51 g03886823
The seal pick points to white layer flaking. This is a normal result of heat treat operations. The gear may be reused.
USE THIS PART AGAIN.
The surfaces of gears begin to wear and the surfaces become smooth when loads are applied to gears. This smooth surface should occur over approximately two-
thirds or more of the length of the gear tooth. Refer to Illustration 52 and Illustration 53.
Illustration 52 g03885234
The gear illustrates normal wear from high hours. This gear may be reused after checking for other types of abnormal wear. The alignment should be adjusted so that the wear will be centered on
the teeth of this gear.
USE THIS PART AGAIN.
Illustration 53 g03885236
Normal wear is shown in this illustration. The machining marks are shown by the arrows. The machining marks are still visible on this gear.
USE THIS PART AGAIN.
Abnormal Wear
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Caterpillar: Confidential Yellow
This section describes the different types of abnormal wear.
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Frosting
Frosting occurs when gear teeth that are mating undergo metal-to-metal contact. The metal contact usually results from an inadequate film of oil between the
surfaces of mating gear teeth. Frosting is not harmful to a gear if pitting has not started. Frosting is not harmful to a gear if the profile has not changed. Frosting
appears as a cloudy gray area on the surface of gear contact. Gears that appear to have signs of frosting can be used again if the gear is free from other types of
damage. Frosting may be a result of the following problems:
• High operating temperatures that cause the viscosity of lubrication to become thin
• High loads
• Incorrect lubrication
• Incorrect part
Other similar problems may result in frosting. Frosting is not harmful to the gear. If the conditions that cause the frosting are not corrected, pitting could result.
Pitting can lead to destructive pitting and spalling.
Illustration 54 g03885406
Frosting appears on the surface of gear contact and frosting usually occurs in an even wear pattern. Frosting is displayed in the illustration as small pits on the surface that are along the pitch line.
Always check for pitting damage and damage to the profile of the gear before reusing a gear that has frosting.
Illustration 55 g03885423
Correct the cause of frosting to avoid pitting. An example of frosting appears as a cloudy gray area on the surface of gear contact. The condition is caused by an inadequate film of oil between two
surfaces of gear teeth that are mating. There is no pitting in this example.
USE THIS PART AGAIN.
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Caterpillar: Confidential Yellow
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Illustration 56 g03887754
Correct the cause of frosting to avoid pitting. The seal pick points to frosting which appears as a cloudy gray area on the surface of gear contact. The condition is caused by an inadequate film of
oil between two surfaces of gear teeth that are mating. There is no pitting in this example.
USE THIS PART AGAIN.
Illustration 57 g03885426
This is an example of frosting. This gear may be reused because there is no pitting. Correct the alignment of the load during the installation process.
USE THIS PART AGAIN.
Illustration 58 g03885431
Pitting (1) is shown on the gear. Frosting (2) is also shown. Frosting (2) is acceptable. Destructive pitting will usually occur with frosting (2). Refer to"Pitting" to determine that pitting (1) is not
destructive. The gear may be reused after determining that pitting (1) is not destructive.
USE THIS PART AGAIN.
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Caterpillar: Confidential Yellow
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Illustration 59 g03886520
Area below frosting appears to be a non-micropitting zone.
USE THIS PART AGAIN.
Illustration 60 g03885437
Reusing the gear depends on the application, operation, and maintenance.
BORDERLINE
Pitting
Pitting is the development of small holes in the surface of a tooth. Pitting is caused by stress that is caused by fatigue from contact on the surface of a gear tooth.
The holes mainly develop on the lower part of a gear tooth near the LPSTC of the drive gear. There are two types of pitting.
Initial Pitting - Initial pitting will usually occur during the period of break-in that is up to 500 hours. Instances of initial pitting will seldom progress into
destructive pitting if the application, operation, and maintenance are correct. Initial pitting will usually stop once the period of break-in is complete.
Destructive Pitting - Destructive pitting will usually occur after the period of break-in up to 500 hours. Destructive pitting will usually be found on most of the
gear teeth. The deep pits will progress into spalling and a fracture if the causes of destructive pitting are not corrected.
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Illustration 61 g03885441
Notice the small pits that are located near the lowest point of single tooth contact on this gear tooth.
Illustration 62 g03885446
Initial pitting (3) should not progress into destructive pitting. Check for other types of abnormal wear before reusing this gear.
USE THIS PART AGAIN.
Illustration 63 g06092920
This Illustration is a magnification of Illustration 62.
USE THIS PART AGAIN.
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Illustration 64 g03885447
The arrows show an instance of initial pitting. Lightly polish the area with a 8T-7765 Surface Reconditioning Pad and oil.
USE THIS PART AGAIN.
Illustration 65 g06092928
This arrow points to initial pitting just at the start of active profile on the gear. Check for other types of abnormal wear before you reuse this gear.
USE THIS PART AGAIN.
Illustration 66 g03886492
The seal pick points to a very small pit. Reuse if similar pitting is not found on most of the gear teeth or consecutive gear teeth.
USE THIS PART AGAIN.
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Illustration 67 g03886748
The illustration shows a small pit.
USE THIS PART AGAIN.
Illustration 68 g03886986
The seal pick points to very small pits.
USE THIS PART AGAIN.
Illustration 69 g03886991
The seal pick points to small pits at high pitch line in a highly loaded portion of the tooth. The pitting appears to elongate which indicates it is becoming destructive.
DO NOT USE THIS PART AGAIN.
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Illustration 70 g03886993
The illustration shows tooth tip pitting. Do not reuse when pitting is found near the tip on multiple teeth. The tooth tip should be an area of no contact.
DO NOT USE THIS PART AGAIN.
Illustration 71 g03887002
This illustration shows multiple pits in the middle of the tooth. Do not reuse as the pitting occurs at the pitch line.
DO NOT USE THIS PART AGAIN.
Illustration 72 g03887015
This illustration shows small tooth pitting that has developed from micro pitting.
DO NOT USE THIS PART AGAIN.
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Illustration 73 g03887023
This illustration shows small tooth pitting that has developed from micro pitting.
DO NOT USE THIS PART AGAIN.
Illustration 74 g03887025
This illustration shows small tooth pitting that has developed from micro pitting.
DO NOT USE THIS PART AGAIN.
Illustration 75 g03887030
This illustration shows small tooth pitting that has developed from micro pitting. The pitting has also occurred at the high loaded region of the tooth.
DO NOT USE THIS PART AGAIN.
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Illustration 76 g03887009
The illustration shows a large deep pit. Do not reuse as large pit will progress into spalling.
DO NOT USE THIS PART AGAIN.
Destructive Pitting
Destructive pitting usually occurs after 500 hours of operation. Destructive pitting can be found on most of the gear teeth. The micro-pitting can lead to destructive
pitting and progress into spalling. The tooth with spalling will eventually fracture.
Illustration 77 g03885496
Destructive pitting is shown in this illustration. The large pits across the Lowest Point of Single Tooth Contact are destructive pits. Destructive pitting can penetrate the case hardened surface of a
gear.
Illustration 78 g06092935
Micro-pitting (4) may occur if the film of lubrication is inadequate. The micro-pitting is a type of destructive pitting that can be caused by metal contact. The micro-pitting is at an early stage.r462het
This
gear can be used again. Determine the cause of insufficient lubrication. Correct the cause of insufficient lubrication before reinstalling the gear. Caterpillar: Confidential Yellow
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Illustration 79 g06092943
The seal pick is showing early hour micro pitting at the root of the tooth. This is early stage wear and the part can be reused.
USE THIS PART AGAIN.
Illustration 80 g03885502
Notice that destructive pitting (6) is much deeper than initial pitting (5). Destructive pitting is near the LPSTC. The destructive pitting has penetrated the case hardened surface.
DO NOT USE THIS PART AGAIN.
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Illustration 81 g03885507 Caterpillar: Confidential Yellow
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Illustration 82 g03887028
Destructive pitting is shown in this illustration. The pit is large and deeper than initial pitting.
DO NOT USE THIS PART AGAIN.
Illustration 83 g03885511
The pitting is extensive with many deep pits on multiple teeth. The pitting has penetrated the case hardened surface.
DO NOT USE THIS PART AGAIN.
Illustration 84 g03885517
Micro pitting is seen on a high load region of the tooth. Reusing the gear depends on application, operation, and maintenance.
BORDERLINE
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Illustration 85 g03885520
The pitting on this gear is at the threshold. Check for other types of abnormal wear. Base the decision on the application, operation, and maintenance of the machine. Inspect the dent to determine
there are no sharp edges present.
BORDERLINE
Illustration 86 g03885522
Micro-pitting (7) and Macro-pitting (8) are shown in the illustration. This gear cannot be reused because the macro pitting is developing into spalling.
DO NOT USE THIS PART AGAIN.
Illustration 87 g03886529
The seal pick points to micropitting. Micropitting at start of active profile. Wear appears normal.
USE THIS PART AGAIN.
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Illustration 88 g03886690
The seal pick points to micropitting.
USE THIS PART AGAIN.
Illustration 89 g03886699
The illustration shows micropitting.
USE THIS PART AGAIN.
Illustration 90 g03886963
The illustration shows micropitting.
USE THIS PART AGAIN.
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Illustration 91 g03886979
The illustration shows micropitting.
USE THIS PART AGAIN.
Illustration 92 g03886982
The seal pick points to micropitting.
USE THIS PART AGAIN.
Illustration 93 g06092951
The seal pick points to micropitting at the root of the tooth.
USE THIS PART AGAIN.
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Illustration 94 g06092959
Micropitting seen at tip of tooth. Part may be reused.
USE THIS PART AGAIN.
Illustration 95 g06092966
Micropitting is seen at tip of tooth. No additional wear is seen.
USE THIS PART AGAIN.
Spalling
Spalling is a type of failure from fatigue that occurs under the surface. Spalling is a result of a small crack that has passed through the face of the gear tooth and
under the case hardened surface. Either destructive pitting or case crushing can cause spalling. Destructive pitting is usually the starting point for spalling. Spalling
travels from the destructive pit up the face of the tooth. Throughout this process, the crack will remain beneath the case hardened surface. When a crack travels
beneath the case hardened surface of a gear tooth, the crack travels along the path of least resistance. As the crack under the surface progresses toward the tip of the
tooth, the case hardened surface will break into small pieces. These pieces will continue to break until the spalling has reached the tip of the tooth. Spalling will
form in the shape of a V. This process happens over a length of time. Once the protective case hardened surface has deteriorated, the weak inner core will be left
unprotected. A tooth that has spalling damage will eventually fracture. Schedule an SOS to detect spalling damage in the drive train. If necessary repairs are not
made, teeth with spalling can fracture. Teeth that fracture can cause significant damage to the drive train. Do not reuse any gear that has spalling damage.
Note: Spalling is often confused with the case crushing. It is important to know the differences.
1. Destructive pitting is the main cause of spalling. Look for instances of destructive pitting. The damage may be due to the case crushing if destructive pitting
is not present.
2. Examine the damaged area. Spalling will not leave pieces of crushed metal. Case crushing will leave pieces of the case.
3. When a gear tooth has spalling damage, the shape of the damage will be in a triangular shape. Damage from a crushed case is usually in a rectangular shape.
Before spalling occurs, the outline in the face of the tooth will be visible. The outline of spalling damage will be a triangular shape and the tip of the triangle will
point downward. Do not reuse any gear with an outline on the face of the tooth in the shape of a triangle.
Once the spalling progresses, the case hardened surface will slowly break. Examples of spalling damage are shown in the next photos. Do not reuse any gear with
spalling damage.
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Illustration 96 g03885587
Notice that the spalling starts at the destructive pitting. The spalling climbs toward the tooth. The spalling is in a triangular shape. Illustrations 97 through 101 show the growth of spalling. The tip
of the tooth (9) and fillet of the tooth (10) will be called out in the following illustrations.
Illustration 97 g03885591
Stage 1
The starting point of spalling is visible. The starting point is shown below the pitch line.
DO NOT USE THIS PART AGAIN.
Illustration 98 g03885598
Stage 2
Stage 2 shows a small crack from fatigue at the surface of the gear. Metal starts to flake off the face of the tooth.
DO NOT USE THIS PART AGAIN.
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Stage 3
The small cracks under the surface will join and the face of the tooth will flake.
DO NOT USE THIS PART AGAIN.
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Illustration 105 g03885748
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A combination of pitting and spalling occurs during the process of transition between pitting and spalling. The wear is due to the sliding and rolling action between
the teeth. A gear with evidence of pitting and spalling should not be used again. Spalling can progress rapidly into a fracture. Illustration 106 is a cross section of
the spalling prior to a fracture.
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Corrosion may be caused by an electrolyte that has entered the lubrication system. The most common electrolyte is water. Corrosion can lead to corrosive pitting.
Correct the cause of corrosion before corrosive pitting occurs. If an electrolyte enters the drive train, the electrolyte can neutralize the additive package in the oil.
Early stages of corrosion are not harmful. Most corroded gears can be used again if pitting has not occurred. During the rebuild, repair the point of entry for the
electrolyte.
Rust is a common type of corrosion. Check for corrosive pitting after you remove the corrosion.
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Scoring can result from metal to metal tooth contact. Scoring can cause vertical scratches that are perpendicular to the pitch line. Scoring begins above the pitch
line and below the pitch line. Scoring develops when sliding action occurs between two mating teeth. Scoring damage should not occur at pitch line because only
rolling action is present at this location. Scoring can occur with inadequate oil, periods of excessive load, speed, and misalignment. Severe scoring will produce an
irregular surface with wrinkles and depressions on the tooth face. Reuse a gear with scoring damage only if the face of the tooth is relatively smooth and only if the
scoring has not altered the shape of the tooth profile. Inspect the gear for cracks with any of the methods for inspecting cracks.
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Case Crushing
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Case crushing is a failure of the case hardened surface of a gear. The case is the surface and the core is the center. The case of a tooth is much harder than the core
of a tooth. Case crushing appears similar to an object that has been pulverized. When case crushing occurs, the softer core may become exposed. The core of a gear
is unable to withstand the normal loads. Gear teeth with crushed cases will quickly fracture. Gears with evidence of case crushing cannot be used again.
• Misalignment
• Overload
• Shock load
Gears with evidence of case crushing should not be reused. Gears should be checked for cracks if shock loading is suspected, or a failure has occurred. Inspect
gears for cracks with any of the methods for inspecting cracks.
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Abrasive Wear
Abrasive wear is caused by small contaminants in the lubrication system such as the following:
• Soil
• Sand
• Metal
The small particles will eventually wear down the surface of the teeth. The small particles can even alter the profile of a gear. Abrasive material can travel
throughout the gears in the drive train and abrasive material can damage other gears as well. Check all the gears in the drive train if one of the gears has abrasive
wear. Light abrasive material will cause the gear to appear dull in color. The smallest contaminants will lightly polish the teeth of a gear. If light abrasive wear is
not corrected, the teeth will become shiny enough to resemble a mirror. Larger sized contaminants will usually produce scratches, cuts, and bruises on the gear
teeth. Large particles can create deep grooves on the face of the tooth. If evidence of abrasive wear is found, correct the source of the contamination immediately.
Gears with limited abrasive wear may be reused if the profile has not changed and the gear does not have any other types of damage.
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g03886108
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This gear has been exposed to a significant amount of abrasive wear. The arrow in this illustration indicates a heavy wear groove. A significant amount of abrasive wear is capable of causing a
depression.
DO NOT USE THIS PART AGAIN.
Nicks
Nicks usually occur when a gear is not handled properly before heat treatment. Because most nicks will occur before heat treatment, a gear with a nick can be
reused.
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Cracks
It is difficult to distinguish visually a difference between a scratch and a crack. Inspect the gear for cracks with any of the methods for inspecting cracks. Refer to
"Metallurgy" for more information about the necessary equipment and procedures that are needed to determine if cracks are present.
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Chipping
The wear pattern should be checked on gears with chipping. Misalignment will cause loading off the end of the tooth. The misalignment can cause chipping.
Multiple teeth typically become chipped under a misaligned load.
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Uneven Contact
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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:
• Damage from foreign objects will affect the distribution of the load.
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• Damage from foreign objects has penetrated the case hardened surface.
Refer to the "Reconditioning" section 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.
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Note: Gears that have damage from the failures of other parts should be inspected closely due to the potential of cracking. Use a dye penetrant to check for cracks
in the dents that are on the teeth.
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Use the gear again if no cracks are found by using a dye penetrant.
Use the gear again if no cracks are found by using a dye penetrant.
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Use the gear again if no cracks are found by using a dye penetrant.
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Rippling
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Lipping
Gear Bores
Bores of gears in drive trains are sensitive to damage. If the gear will be reused, the bore must not have any wear or damage. A good light source is required to
inspect fully the bore of a gear.
Refer to"Prepare the Area for Inspection" to clean the bore of the gear. If the gear bore has stains that cannot be removed with 8T-7765 Surface Reconditioning Pad
and solvent, do not reuse the gear. A gear with minimal damage to the bore can be reused. Make a careful decision on reusing any gear bore because gear bores are
sensitive to damage. If a gear bore has more than one type of damage, the gear bore should not be reused. Gears with lightly damaged gear bores may be reused if
each of the following conditions are true:
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• Damage does not extend across more than 25% of the width of the thrust face.
Planetary gear bores are unique to other gear bores in drive trains. Planetary gears are highly loaded. It is important to inspect carefully all planetary gear bores.
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Damage to a bore with a replaceable bearing race occurs when the bearing cup rotates inside the gear bore. Planetary gears with replaceable bearing races can often
be used again if the race has only crept in the bore. Before reusing the gear, check the size of the gear bore to determine that the bore is still within specifications
for reusability. Refer to Reuse and Salvage Guideline, SEBF8185, "Salvage Procedure for Final Drive Planet Gear Used in Off-Highway Trucks" for more
information about gears that have replaceable bearing races.
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Splines
Splines should be checked for wear with a seal pick. The seal pick should be held perpendicular to the spline. If the pick is stopped by any of the wear steps, do not
reuse the gear. Visually check for other damage on the spline before reusing the gear. Refer to the Inspecting the Splines section within Reuse and Salvage
Guideline, SEBF8443 for proper Inspection and Measuring procedures.
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Thrust Faces
The thrust face of a planet gear, sun gear, or side gear should not have smears or heat checks. Heat checks are shallow cracks that interrupt the film of lubrication.
Heat checks can shave off material from the thrust bearing. Gears with light damage on the thrust face can be used again. Light scratches are acceptable only when
the scratches do not stop a seal pick. If there is a sharp edge on the thrust face, remove the edge with 6V-2010 Polishing Stone and oil.
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Caterpillar: Confidential Yellow
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