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Introduction
Table 1
Revision Summary of Changes in SEBF8093
Updated boilerplate information, added clarity to Illustrations, tables, verbiage, and
13 document layout. Corrected several Tolerances throughout this document. Added
information for 20 part numbers.
12 Added 22 part numbers.
11 Added 3 part numbers.
10 Added 10 part numbers.
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© 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 information enables Caterpillar dealers and customers to
benefit from cost reductions. Every effort has been made to provide the most current information that
is known to Caterpillar. 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.
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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
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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. Refer to Illustration 2 for an example of a “WARNING” Safety Alert
Symbol.
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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.
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
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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. Caterpillar dealers can supply the most current information.
Summary
This guideline provides information, which aids in the determination of the reusability of the
planetary carrier in the final drive.
This guideline provides the procedures necessary to determine the reusability of planetary final drives.
Life will vary depending on application, load, lubrication, and environment.
This guideline contains the latest standards of engineering, which will help minimize owning and
operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part
meets the specifications within this guideline and the part is intended for a similar application. Use
this guideline to determine whether a part should be reused. Do not install a part that is not
reusable. During reconditioning, correct any condition that might have caused the original failure.
The dimensions and tolerances provided are to return a part / component to specification. The
dimensional information alone is not solely used to condemn a part from reuse. Follow visual
inspections and the "Crack Detection Methods" section for further guidance.
References
Table 2
References
Media
Publication Type & Title
Number
"Gear Tooth Inspection"
https://channel1.mediaspace.kaltura.com/media/Gear+Tooth+Inspection/1_5ujdi5zp
Channel1
"Why Reuse and Salvage Parts"
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Reuse and Salvage Guidelines
SEBF8163
"Procedures to Salvage Thrust Faces on Planetary Carriers"
SEBF8187
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Table 3
Required Tooling and Equipment
Part Number Description Designation
— (1) Personal Protective Equipment (PPE) Personal Protection
Component
— (2) Clevis/ Shackle Repositioning
and Movement
— (2) Lifting Eye Assemblies
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Component
Repositioning
and Movement
Component
— (2)
Tool (Cribbing) Repositioning
and Movement
Component
— Suitable Lifting Device Repositioning
and Movement
1U-7262 Telescoping Magnet General Tooling
Automatic Tape Measure (1-inch X 26- ft) Measurement
1U-9367
25.4- mm x 8- m Checks
Caliper Profile
4S-9405
304.8 mm (12.00 inch) Measurement
Tool
Measurement
5P-3920 Rule
Checks
304.8 mm (12.00 inch)
Feeler Gauge Thickness
8H-8581 0.038 - 0.635 mm Measurement
(0.0015 - 0.0250 inch) Checks
Tools (Micrometer) Internal
385-9422 Internal Measurement
(2 - 24 inch) Checks
Tool (Ruler) Measurement
386-3364
1,000.0 mm (39.37 inch) Checks
Micrometers External
431-4150 External Measurement
0 - 25 mm (0 - 1 inch) Checks
Instrument Group
Micrometer, Inside
473-8688 2.00 - 12.00 inch Internal
or Measurement
473-8689 Instrument Group Checks
Micrometer, Inside
50 - 300 mm
Instrument Group External
473-8690 Micrometer, Outside Measurement
0.00 - 4.00 inch Checks
473-8691
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Surface
Preparation
/ De-burring
Surface
1U-6846 Abrasive Disc Preparation
/ De-burring
Surface
4C-3770 Grinding Wheel Preparation
/ De-burring
Wheel Surface
4C-8514 (2 x 1 inch) Preparation
(60 Grit) / De-burring
Grinding Wheel (F-Grade) Surface
4C-8515 (2 x 1 inch) Preparation
(120 Grit) / De-burring
Surface
Die Grinder
222-3076 Preparation
(Right Angle)
/ De-burring
Brush Surface
254-5319 76.2 x 50.8 mm Preparation
(3.00 x 2.00 inch) / De-burring
9U-7377 (3) Metal Marking Pen Parts Marking
6V-2010 Polishing Stone Gear Polishing
1U-9918 Brush General Cleaning
1U-5512 Abrasive Material (Roll) General Cleaning
8T-7765 Surface Reconditioning Pad (180 Grit) General Cleaning
162-5791 Towel General Cleaning
MOP Small Gear/
— Large Rubber Band Spline Wear
Inspection
Measurement
Tool Group Between / MOP
549-3500
Gage Pins Gear/ Spline
Wear Inspection
Precision Gage Pins (4) Measurement
Ø 2.3825 mm Between / MOP
—
(0.09380 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
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Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
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Illustration 3 g03794147
Typical burr removal Tooling.
(A) Die Grinder, Right Angle
(B) Wheel Grinder, Group
(C) Conditioning Discs, Disc pad Holder, and Threaded Shaft
(D) Flapper Wheel
• Before you inspect a part, clean the part thoroughly to ensure that all components are free from
rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of
an unacceptable defect.
• Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to
prevent damage to the part when you lift the part.
• Do not use pressurized air to dry internal components. Compressed air has moisture and
contaminants that can cause premature failure of internal components.
• Inspect all fasteners that have been removed, refer to SEBF8728, "Specifications for Inspection
of Driveline Fasteners" for more information.
• Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done
immediately after cleaning. Carefully store the parts in a clean container.
• Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and
free from raised material resulting from rust, nicks, and dents.
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The code is a Cat standard and is used to record the history of a component. The code will identify the
number of rebuilds and hours at the time of each rebuild. This information is important and should be
considered for any decision to reuse a component.
Ensure that the mark is not covered by a mating part. Use a metal marking pen to mark the code onto
the component.
NOTICE
Do not use numbering stamp punches to mark internal components.
The impact from striking the stamp will cause an abnormal stress
riser. The added stress riser may cause premature part failure.
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Illustration 4 g06124077
DO NOT use numbering stamp punches to mark internal components.
The procedure for marking components is a Cat 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.
Example 1
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Illustration 5 g03856853
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Typical Example
Illustration 5 shows code (1-15). The first number (1) indicates that the gear had been repaired once.
The second number (15) indicates that there were 15,000 hours on the gear at the time of repair.
Example 2
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Illustration 6 g03748362
Example
This coding can be used by all dealers and will help with identification at time of repair. Identification
can be especially helpful if units that have been rebuilt are sold into different territories. As rebuilds
are completed, the previous markings should be left on the component.
Illustration 6 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 gear had been rebuilt twice. The second number
(10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.
Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in
Illustration 6. In this example, the gear has a total of 22,000 hours.
Example 3
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Illustration 7 g03519882
Typical Example
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(A) Mark the planet pin on either end using a metal marking pen.
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Illustration 8 g06320845
Typical Example of Final Drive Wheel Group - Without Brakes
(1) Spindle
(2) Wheel
(3) Reaction Hub
(4) Planetary Carrier
(5) Planetary Gear
(6) Planetary Shaft
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Illustration 9 g06321222
Typical Example of Final Drive Wheel Group - With Brakes
(1) Spindle
(2) Wheel
(3) Hub
(4) Planetary Carrier
(5) Planetary Gear
(6) Planetary Shaft
(7) Service Brake Group
Measurement Techniques
NOTICE
Precise measurements shall be made when the component and
measurement equipment are at 20° C (68° F). Measurements shall be
made after both the component and measurement equipment have had
sufficient time to soak at 20° C (68° F). Ensuring that both the surface
and core of the material is at the same temperature will increase the
accuracy of the measurement taken.
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Outside Micrometers
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Illustration 10 g06208395
Typical example of calibrating outside micrometer (A).
(A) Outside Micrometer
Measurement Tooling include precision inside and outside diameter micrometers capable of
measuring four decimal places in inches or three decimal places in millimeters. Measurement Tooling
should be calibrated using gauge blocks certified to a national standard such as the National Institute
of Standards and Technology (NIST).
Inside Micrometer
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Illustration 11 g06208411
Typical example of calibrating inside micrometer (B).
(B) Inside Micrometer
Bore Diameters
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Illustration 12 g06318221
Typical example of measuring bore Inside Dimension (ID) of a wheel.
(A) Indicates the diameter of the bore.
(B) Indicates the overall thickness of the material.
Note: Measurements taken on the edge of a bore may not give an accurate measurement.
To ensure adequate life of the components, this document contains precise tolerances for
measurements taken on various features. Ensure that several sample measurements are taken at
different locations on the same feature. Measure diameters of internal bores in six places to identify
tapered and or oval conditions. Refer to Illustration 12.
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Illustration 13 g06318222
Typical example of measuring an Outside Diameter (OD) Dimension of a spindle.
(C) Indicates the diameter of the shaft.
(D) Indicates the overall measurable length of the shaft journal.
To ensure adequate life of the components, this document contains precise tolerances for
measurements taken on various features. Ensure that several sample measurements are taken at
different locations on the same feature. Measure diameters of journals in six places to identify tapered
and or oval conditions. Refer to Illustration 13.
Bores will usually show a contact area from the shaft that may be worn slightly. The bore may also
have damage from some broaching, fretting, adhesion, or impact. If any of the following conditions
exist, the planetary carrier shall not be reused:
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• The bore has a wear step that will stop a seal pick.
Inspection Procedure
Pin bores and pins can be cleaned with cleaner for parts and a surface reconditioning pad that
will not remove metal.
Note: An adequate light source is necessary to inspect pin bores. An optical magnifier may also
be used.
3. Inspect the bore with a seal pick to detect any wear steps.
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Illustration 14 g06319011
Typical example of an internal planetary carrier with in bores on a dual plane.
(A) Pin Bore
Table 4
Record Actual Dimensions
Final Drive Internal Planetary Refer to the "Measurement Techniques" section for
Carriers Pin Bore Tolerances (1) the proper techniques and number of measurements
to be taken.
Part Tolerance
Measurement Measurement Measurement
Number (A)
Ø 42.342 ± 0.013 mm
4E-2166 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 35.279 ± 0.013 mm
8R-0233 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
8R-2198 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 35.279 ± 0.013 mm
8R-2537 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
8R-4571 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
8R-5959 Ø 77.605 ± 0.015 mm
A1 = A2 = A3 =
137-3506 (3.0553 ± 0.0006 inch)
Ø 120.03 ± 0.015 mm A1 = A2 = A3 =
8R-5960
(4.7256 ± 0.0006 inch)
9C-6027 A1 = A2 = A3 =
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Ø 48.007 ± 0.013 mm
(1.8900 ± 0.0005 inch)
Ø 30.026 ± 0.013 mm
110-5187 A1 = A2 = A3 =
(1.1821 ± 0.0005 inch)
Ø 48.007 ± 0.013 mm
119-1096 A1 = A2 = A3 =
(1.8900 ± 0.0005 inch)
Ø 70.057 ± 0.013 mm
129-4300 A1 = A2 = A3 =
(2.7581 ± 0.0005 inch)
Ø 35.278 ± 0.01 mm
136-4838 A1 = A2 = A3 =
(1.3889 ± 0.0004 inch)
Ø 42.342 ± 0.013 mm
218-3174 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 53.015 ± 0.013 mm
270-7672 A1 = A2 = A3 =
(2.0872 ± 0.0005 inch)
Ø 77.605 ± 0.015 mm
244-1099 A1 = A2 = A3 =
(3.0553 ± 0.0006 inch)
Ø 42.342 ± 0.013 mm
327-2232 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
360-9857 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
361-8064 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
386-0500 (2.3388 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
364-2561 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
370-4416 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
386-0501 (2.3388 ± 0.0005 inch)
Ø 59.406 ± 0.013 mm
388-1399 A1 = A2 = A3 =
(2.3388 ± 0.0005 inch)
Ø 95.347 ± 0.015 mm
419-6354 A1 = A2 = A3 =
(3.7538 ± 0.0006 inch)
(1) Note: The most current part number is identified in bold font when multiple part numbers are in a cell.
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Illustration 15 g06319028
Typical example of an external planetary carrier with in bores on a dual plane.
(B) Pin Bore
Table 5
Record Actual Dimensions
Final Drive External Planetary Refer to the "Measurement Techniques" section for
Carriers Pin Bore Tolerances (1) the proper techniques and number of measurements
to be taken.
Part Tolerance
Measurement Measurement Measurement
Number (B)
1V-1409 Ø 31.768 ± 0.013 mm
A1 = A2 = A3 =
9K-4887 (1.2507 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
1V-2281 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 35.279 ± 0.013 mm
1V-3335 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 84.821 ± 0.013 mm
1V-5059 A1 = A2 = A3 =
(3.3394 ± 0.0005 inch)
Ø 77.605 ± 0.013 mm
2V-4149 A1 = A2 = A3 =
(3.0553 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
2V-5722 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
Ø 84.821 ± 0.013 mm
3D-4222 A1 = A2 = A3 =
(3.3394 ± 0.0005 inch)
A1 = A2 = A3 =
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Illustration 16 g06319051
Typical example of a planetary carrier with pin bores on a single plane.
(C) Pin Bore
Table 6
Record Actual Dimensions
Final Drive Planetary Carrier Pin Bore (Single Refer to the "Measurement Techniques"
Plane) Tolerances (1) section for the proper techniques and number
of measurements to be taken.
Fit Tolerances
Part (C)
Limit Measurement Measurement Measurement
Number (2)
Minimum Maximum
216-8118 Ø 45.000 mm Ø 45.039 mm
H8 A1 = A2 = A3 =
292-5438 (1.7717 inch) (1.7732 inch)
Ø 39.80 mm
216-8120 — (1.567 inch) — A1 = A2 = A3 =
Reference
Ø 45.000 mm Ø 45.039 mm
293-2098 H8 A1 = A2 = A3 =
(1.7717 inch) (1.7732 inch)
(1) Note: The most current part number is identified in bold font when multiple part numbers are in a cell.
(2) Limits and Fit Tolerances per ISO 286.
Reusability of Gearing
Accurate inspection is critical for the life of any gear. The maximum life of any drive train can be
obtained through proper inspection and repair procedures. If an unacceptable gear is reused, then there
is a good possibility that the gear will fail. The gear that failed will destroy other components in the
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drive train. The technician that is inspecting should be familiar with all types of gear wear and
damage. The most common reasons for gear failure are described in this guideline. Decisions
regarding reuse and salvage of gears are aided in thorough inspections.
Note: Some gearing applications run in one direction. Thus wear should only occur on one side of the
gear. If the inspection suggests that a gear is worn, then flipping the gear may be an option thus using
the other side of the tooth. Most likely application of gear flipping will be to those gears that have
symmetrical features.
Visual Inspections - Use the following general examples as a guide to inspect for the following
common wear types, defects, critical part locations, and features:
• Corrosion
• Cracks
• Wear Steps
• Fretting
Reference: SEBF8193 Reuse and Salvage Guidelines, "Reusability of Drive Train Gears" for more
detailed information regarding general gear inspection.
Dimensional Checks - Refer to the "Measurement Techniques" section before dimensional checks
are performed. Refer to each components illustration and table of dimensions and acceptable
tolerances to inspect for excessive wear. In addition to these dimensional inspections, each part must
also pass one of the Non-Destructive Testing (NDT) methods listed in the "Crack Detection Methods"
section.
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Illustration 17 g06085440
(A) Tooth Face
(B) Fillet Area
Check fillet area (B) with a seal pick. Fillet area (B) must be free from notches or wear steps.
Note: If steps are found in the fillet area of a gear tooth, then DO NOT USE THE PART AGAIN.
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Illustration 18 g03427659
Typical example of a gear inspection using reflective paper.
Utilize a clean, white piece of paper with a dull finish that to reflect light onto the face of each gear
tooth during an inspection.
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Illustration 19 g06085442
Illustration of view through eye piece of a pocket microscope.
If necessary use a microscope with light for enhanced view and to measure the defects. Refer to
Tooling Table 3 for the part number.
Minor abrasive wear (C) may indicate that there is contamination in the gear case. Once the source of
contamination has been found then, OK TO USE PART AGAIN.
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Illustration 20 g06033556
Typical example of a planetary gear with evidence of corrosion (D), OK TO USE THIS PART AGAIN.
(D) Corrosion
The presence of corrosion (D) may be due to contamination or as a result of the process used to clean
the part. Identify the source of corrosion (D), then OK TO USE PART AGAIN.
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Illustration 21 g06033582
Typical example of spalling (E) on tooth face, DO NOT USE PART AGAIN.
(E) Spalling
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Illustration 22 g06033587
Typical example of pitting (F) on tooth surface, DO NOT USE PART AGAIN.
(F) Pitting
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Illustration 23 g03708114
Typical example of crack shown under Liquid Penetrant Testing (PT) of a gear, DO NOT USE THIS PART AGAIN.
Refer to the "Liquid Penetrant Testing (PT)" section for testing instructions.
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Illustration 24 g06085444
Typical example of cracks found using Wet Magnetic Particle Testing (MPT), DO NOT USE THIS PART AGAIN.
Refer to the "Wet Magnetic Particle Testing (MPT)" section for testing instructions.
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Illustration 25 g03427695
Typical example of a planetary gear that requires further inspection of the bore.
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Illustration 26 g06008970
Typical example of brinelling found during a planetary gear bore inspection, DO NOT USE THIS PART AGAIN.
Inspect planetary gear bore for pitting, heat cracks, and brinelling. If pitting, heat cracks, or brinelling
are found on the planetary gear bore then, DO NOT USE PART AGAIN.
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Illustration 27 g06026642
Typical example of cleaning a planetary gear bore. After cleaning a planetary gear bore, OK TO USE THIS PART
AGAIN.
(G) Planetary gear bore before cleaning.
(H) Planetary gear bore after cleaning.
Note: Planetary gear bores can be cleaned with cleaner for parts and a nonmetallic pad for
rubbing that will not remove metal.
2. Visually inspect the planetary gear bore for damage and wear.
Note: An adequate light source is necessary to inspect planetary gear bore. An optical
magnifier may also be used.
3. Inspect the planetary gear bore with a seal pick to detect any wear steps.
4. Perform Wet Magnetic Particle Testing (MPT). Refer to the "Wet Magnetic Particle Testing
(MPT)" section for testing instructions.
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Extreme Pressure (EP) lubricants can cause corrosion. These lubricants are not recommended for use
in Caterpillar final drives.
Check the bores of all planetary gears for other surface defects (cracks, pits, and so on).
Refer to Table 7 for the tolerances for reusability of the final drive planetary gear bores.
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Illustration 28 g06322321
Typical example of stains on the surface of the gear bore.
If stains can be removed from the gear bore surface with reconditioning pad, USE THIS PART
AGAIN.
If pitting are found in the stained areas, then DO NOT USE GEAR AGAIN.
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Illustration 29 g06322341
Typical example of corrosion pitting on the gear bore. Due to surface pitting, DO NOT USE THIS PART AGAIN. The
pitting will progress into spalling.
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Illustration 30 g06322347
Wash board texture and appearance on surface of the gear bore is called "Brinelling", DO NOT USE THIS PART
AGAIN.
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Illustration 31 g06318873
Typical example of planetary gear bore (D) measurement.
(D) Bore
Table 7
Record Actual Dimensions
Final Drive Planetary Gear Bore Refer to the "Measurement Techniques"
Tolerances (1) section for the proper techniques and number
of measurements to be taken.
Part Tolerance
Measurement Measurement Measurement
Number (D)
1V-8605 Ø 77.625 ± 0.013 mm
A1 = A2 = A3 =
9C-8074 (3.0561 ± 0.0005 inch)
2V-5710 A1 = A2 = A3 =
9C-8072 Ø 57.127 ± 0.01 mm
9U-3124 (2.2491 ± 0.0004 inch)
186-4439
Ø 51.872 ± 0.01 mm A1 = A2 = A3 =
3K-7020
(2.0422 ± 0.0004 inch)
Ø 43.218 ± 0.008 mm
3K-7110 A1 = A2 = A3 =
(1.7015 ± 0.0003 inch)
4D-1569 Ø 86.068 + 0.020 - 0.008 mm
A1 = A2 = A3 =
4E-0403 (3.3885 ± 0.0008 - 0.00031 inch)
4E-3638 Ø 112.44 ± 0.01 mm
A1 = A2 = A3 =
162-0191 (4.4268 ± 0.0004 inch)
4V-0093 A1 = A2 = A3 =
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Ø 51.872 ± 0.01 mm
(2.0422 ± 0.0004 inch)
Ø 124.663 ± 0.02 mm
4V-9867 A1 = A2 = A3 =
(4.9080 ± 0.0008 inch)
Ø 77.625 ± 0.013 mm
5K-4180 A1 = A2 = A3 =
(3.0561 ± 0.0005 inch)
Ø 75.86 ± 0.03 mm
5V-1480 A1 = A2 = A3 =
(2.9866 ± 0.0012 inch)
Ø 110.922 ± 0.025 mm
5V-4075 A1 = A2 = A3 =
(4.3670 ± 0.0010 inch)
5V-4699 Ø 124.663 ± 0.02 mm
A1 = A2 = A3 =
9U-3869 (4.9080 ± 0.0008 inch)
Ø 51.872 ± 0.010 mm
5V-8921 A1 = A2 = A3 =
(2.0422 ± 0.0004 inch)
6K-9129 Ø 41.303 ± 0.010 mm
A1 = A2 = A3 =
7K-7237 (1.6261 ± 0.0004 inch)
Ø 43.218 ± 0.008 mm
6S-3490 A1 = A2 = A3 =
(1.7015 ± 0.0003 inch)
Ø 193.794 ± 0.020 mm A1 = A2 = A3 =
6W-0299
(7.6297 ± 0.0008 inch)
Ø 43.221 ± 0.008 mm A1 = A2 = A3 =
7G-2476
(1.7016 ± 0.0003 inch)
Ø 43.221 ± 0.008 mm A1 = A2 = A3 =
7G-2486
(1.7016 ± 0.0003 inch)
Ø 58.298 ± 0.01 mm A1 = A2 = A3 =
7G-3467
(2.2952 ± 0.0004 inch)
Ø 66.274 ± 0.013 mm A1 = A2 = A3 =
7G-3468
(2.6092 ± 0.0005 inch)
Ø 66.274 ± 0.013 mm A1 = A2 = A3 =
7G-3470
(2.6092 ± 0.0005 inch)
Ø 112.44 ± 0.01 mm
8K-0004 A1 = A2 = A3 =
(4.4268 ± 0.0004 inch)
Ø 51.872 ± 0.01 mm
8R-2199 A1 = A2 = A3 =
(2.0422 ± 0.0004 inch)
8R-7812 Ø 43.218 ± 0.008 mm
A1 = A2 = A3 =
253-8920 (1.7015 ± 0.0003 inch)
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View Image
Illustration 32 g06320721
Typical example of a slip fit shaft with minor fretting, OK TO USE THIS PART AGAIN.
Fretting may occur on the contact surface of the shaft and carrier. Shafts can be reused if less than
50% of the contact width and 25% of the shaft diameter is affected. A shaft diameter in question
should be measured and compared with the manufacturer's specifications.
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Illustration 33 g06319268
Fretting on a planetary shaft.
If the shaft meets all other specifications, USE THIS PART AGAIN.
Refer to Table 8 for the dimensional tolerances for reusability of the planetary shaft.
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View Image
Illustration 34 g06318906
Typical example of planetary shaft measurements.
(E) Width
(F) Length
Table 8
Record Actual Dimensions
Refer to the "Measurement Techniques"
Planetary Shafts Tolerances (1)
section for the proper techniques and numb
of measurements to be taken.
Part Width Tolerance Length Tolerance
Measurement Measurement
Number (E) (F)
Ø 95.321 ± 0.01 mm 231.6 ± 0.5 mm
1V-6663 C1 = C2 =
(3.7528 ± 0.0004 inch) (9.12 ± 0.02 inch)
2D-6633
Ø 84.795 ± 0.008 mm 165.1 ± 0.5 mm
2G-6572 C1 = C2 =
(3.3384 ± 0.0003 inch) (6.50 ± 0.02 inch)
101-1505
2G-6571
Ø 59.380 ± 0.008 mm 162.6 ± 0.5 mm
3D-8416 C1 = C2 =
(2.3378 ± 0.0003 inch) (6.40 ± 0.02 inch)
101-1504
2V-1074 Ø 35.253 ± 0.008 mm 93.7 ± 0.5 mm
C1 = C2 =
5K-0927 (1.3879 ± 0.0003 inch) (3.69 ± 0.02 inch)
Ø 77.577 ± 0.010 mm 165.10 ± 0.5 mm
2V-4148 C1 = C2 =
(3.0542 ± 0.0004 inch) (6.500 ± 0.020 inch)
2V-5737 Ø 44.397 ± 0.008 mm 140 ± 1.0 mm
C1 = C2 =
186-4440 (1.7479 ± 0.0003 inch) (5.5 ± 0.04 inch)
C1 = C2 =
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View Image
Illustration 35 g06369426
Typical example of planetary shaft measurement of part number 215-7488.
Table 9
Record Actual Dimensions
Planetary Shafts Tolerances Refer to the "Measurement Techniques" section
Part Number 215-7488 for the proper techniques and number of
measurements to be taken.
Location Minimum Maximum Measurement Measurement Measurement
78.0 mm 78.2 mm
G
(3.07086 inch) (3.07873 inch)
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H 30.0 mm 30.05 mm
(1.18110 inch) (1.18307 inch)
25.6 mm 25.7 mm
J
(1.00787 inch) (1.01181 inch)
7.5 mm 8.5 mm
K
(0.29528 inch) (0.33465 inch)
Ø 45.33 mm Ø 45.35 mm
L C1 = C2 = C3 =
(1.78464 inch) (1.78543 inch)
Ø 45.3 mm Ø 45.5 mm
M C1 = C2 = C3 =
(1.78346 inch) (1.79134 inch)
Ø 44.9 mm Ø 44.95 mm
N C1 = C2 = C3 =
(1.76771 inch) (1.76968 inch)
Ø 39.989 mm Ø 40.000 mm
P C1 = C2 = C3 =
(1.57437 inch) (1.57480 inch)
Ø 34.85 mm Ø 35.0 mm
R C1 = C2 = C3 =
(1.37204 inch) (1.37795 inch)
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Illustration 36 g06369452
Typical example of planetary shaft measurement of part number 215-8060.
Table 10
Record Actual Dimensions
Planetary Shafts Tolerances Refer to the "Measurement Techniques" section for
Part Number 215-8060 the proper techniques and number of measurements
to be taken.
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The spindles and splines must be inspected prior to any repair. These splines are subject to high loads.
This makes accurate inspection essential. Splines should be inspected immediately after removal. If
the splines are not immediately inspected, hydraulic oil should be applied to each machined surface to
prevent rust or corrosion. If spline on spindle is cracked, DO NOT USE AGAIN.
Always use proper lifting devices for the safety of the operator and to prevent damage to the
machined surface. Personal protective Equipment (PPE) should be worn always for the operator's
protection.
The key element to analyzing damage on final drive splines is determining if the damage will progress
to a failure before the next Planned Component Rebuild (PCR). The application and size of splines
are important in determining if the damage will progress.
Spline wear is the result of relative motion between mating spline teeth. High loading, insufficient
lubrication, vibration, and abrasive materials may result in wear. Typically, splines can be reused if
less than a 0.203 mm (0.0080 inch) wear step exists. When spline wear is excessive, movement of the
joint increases causing misalignment and an imbalance which increases the rate of the deterioration of
the spline. Excess clearance between splines will also create shock loading during speed, load, and/or
direction changes.
There is normally a small amount of relative motion between mating spline teeth. Uneven contact
patterns on teeth of the splines are the result of misalignment of one or both of the mating splines. The
spline teeth will not fully engage if the teeth are misaligned. This means that only a portion of each
tooth is carrying the full load. Misalignment of teeth causes high contact pressures on the portion of
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the tooth that carries the load. The damage on the surface that is caused by these conditions is spline
wear and fretting. Misalignment can be identified by the uneven contact pattern on the spline teeth.
Misalignment of the spline can be caused by worn bearings, damaged bearings, bores of the carrier,
faces of the carrier, or shafts. If any spline displays uneven contact patterns, be sure to check for
misalignment and correct the problem.
Misaligned splines can be reused if the splines meet the specifications for reusability.
Numerous broken spline teeth may be the result of failure from bending fatigue. The operational loads
create tensile stress in the fillet on the loaded side of the tooth. With enough high loads and cycles,
these stresses can cause cracks from fatigue. A crack from fatigue could cause a tooth to separate
from the parent metal. Cracking can also occur between the root of the tooth and a bolt hole or inside
diameter of the part.
Visual Inspection
Splines can be visually inspected. To ensure the best results, a magnifying glass and a strong light
source such as sunlight are recommended. It can also be difficult to distinguish between small
scratches and small cracks. If unable to determine scratches from hair line cracks, then perform
Liquid Penetrant Testing (PT) or Wet Magnetic Particle Testing (MPT).
Ensure to inspect all spline. If damaged spline is found, all spline that mate to it and all splines that
are 180° from the damaged spline should be reinspected for possible fatigue from bending. Refer to
"Crack Detection Methods" section for Non-Destructive Testing (NDT) procedures.
If spline is damage from misalignment, then DO NOT USE AGAIN. Abnormal wear will not permit
full tooth contact thus result in high contact pressures.
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Illustration 37 g01716065
Typical example of check spline for wear steps with a seal pick.
If the splines stop the seal pick on the worn area, measure the splines before reusing. Generally, a
0.152 mm (0.0060 inch) wear step will stop a seal pick.
Typically spline can be reused if step measures less than 0.203 mm (0.0080 inch)
If spline has no significant wear (J) steps, then OK TO USE THIS PART AGAIN.
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Illustration 38 g01240327
Internal spline with full contact and even wear, OK TO USE THIS PART AGAIN.
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Illustration 39 g01240340
Spline shows signs of even loading and full contact, OK TO USE THIS PART AGAIN.
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Illustration 40 g01240365
The spline has an external wear step, but the spline meets specifications for reusability. Corrosion from fretting is also
apparent. This corrosion is due to lack of lubrication, OK TO USE THIS PART AGAIN.
Wear Steps
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Illustration 41 g06122439
Typical example of an internal spline with significant wear (L) steps, DO NOT USE AGAIN.
(L) Wear
View Image
Illustration 42 g06319105
Check the ends of location of the engagement of the splines.
If wear steps are found on either external or internal splines, drag a seal pick across the step. If the
wear step stops the pick and measures more than 0.203 mm (0.0080 inch), then DO NOT USE
AGAIN.
Remember to check the ends of the location of the engagement of the splines. If splines are not worn
evenly, DO NOT USE THE PART AGAIN. Check mating spline for alignment.
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View Image
Illustration 43 g06324680
Typical example of corrosion from poor storage techniques, clean inspect for pitting. If excessive pitting, then DO NOT
USE THIS PART AGAIN.
Damage to Teeth
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Illustration 44 g06324678
Typical example of spline damage from poor handling, but no signs of cracking. Use a polishing stone to smooth any
raised material from the indentation, OK TO USE THIS PART AGAIN.
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View Image
Illustration 45 g06324674
Typical example of spline damage from poor handling with a sign of cracking. Use a polishing stone to smooth any
raised material from the indentation. If evidence of crack after removal of raised material, then DO NOT USE THIS
PART AGAIN.
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Illustration 46 g01240382
A spline is cracked in the area of the root and the crack has progressed into the adjacent splines, DO NOT USE THIS
PART AGAIN.
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Illustration 47 g06324684
Typical example of a crack extending from the spline into the bolt hole. The bolt hole is weakened and premature failure
will result, DO NOT USE THIS PART AGAIN.
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Illustration 48 g06324686
Typical example of a crack in the root of the spline tooth, DO NOT USE THIS PART AGAIN.
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Illustration 49 g06321306
Typical wear step on an internal spline.
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Illustration 50 g06075213
Typical example of taking an internal spline measurement.
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Illustration 51 g06181320
(G) 1, (G) 2, and (G) 3 Measurement Locations
The location of the gage pins at 60° intervals is critical to the formula. These three locations will
provide information about the wear of the part. Refer to Illustration 51.
An inside micrometer must be positioned to measure the shortest distance points on the gage pins.
This procedure will provide the measurement of the wear on the spline. The gage pin diameter for
each individual part is determined by the size and pitch of the spline.
Calculate the average of the values taken from locations (G) 1, (G) 2, and (G) 3. The difference
between the measurements will determine if there is an out of round condition caused by poor load
distribution on the splines.
Place gage pins at 60° intervals on the planetary carrier. The location of the gage pins at 60° intervals
is critical to the formula. These three locations will provide information about the wear of the part.
Steps 1 through 4 demonstrate an example of the process to calculation internal spline roundness.
Provided is an example of performing spline reusability calculations of a reaction hub part number
137-8628 for a 994 wheel loader. Refer to Table 20 for specifications:
1. Take measurements at locations (G) 1, (G) 2, and (G) 3 between gage pins. Taken measurements
are recorded in Table 11.
Table 11
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Recording 3 Measurements Taken
Location Measurements Taken
G1 Ø 465.705 mm (18.3348 inch)
G2 Ø 465.920 mm (18.3433 inch)
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2. Add the measurements together to calculate the sum. The sum of the three measurements is
1397.805 mm (55.0316 inch).
Table 12
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Calculating Sum of 3 Measurements Taken
Measurement
Calculation SUM Total =
Locations
G1, G2, and G3 G1 + G 2 + G3 1397.805 mm (55.0316 inch)
3. Divide the sum of the measurements taken by 3 to calculate the average. The calculated average
of 465.935 mm (18.3439 inch) is less than the reusability specification of 466.167 mm
(18.3530 inch). In this example the internal spline is within the reusability specification and
therefore passes this test, proceed to Step 4.
If the internal spline is greater than the reusability specification, then DO NOT USE THE
PART AGAIN.
Table 13
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Calculating Average of the 3 Measurements Taken
Location Calculations Results
(G1 + G2 + G3) / 3
G1, G2, and G3 Ø 465.935 mm (18.3439 inch)
= Avg
Refer to
Reusability
Specifications in Ø 466.17 mm (18.353 inch)
Specification
Table 20.
Avg > Reusability Avg = Ø 465.935 mm (18.3439 inch) < than
Specification = Fail Reusability Specification of Ø 466.17 mm
Avg Specification
Avg < Reusability (18.353 inch)
Specification = Pass Pass
4. The difference between the high measurement and the low measurement determines if the
spline is round. Out-of-round or ovality can cause uneven load distribution on the splines.
Calculate the difference between the high and the low measurement by subtracting the high
measurement of Ø 466.180 mm (18.3535 inch) from the low measurement of Ø 465.705 mm
(18.3348 inch). The difference between the high and low measurements determine if the spindle
can be reused. The difference in this example is 0.475 mm (0.0187 inch).
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Maximum difference between the high measurement and the low measurement allowance of
0.47 mm (0.019 inch) and the actual difference of 0.475 mm (0.0187 inch) is greater than the
allowable maximum difference.
If the maximum difference between the high measurement and the low measurement is greater
than 0.47 mm (0.019 inch) the internal spline is considered to be out-of-round or oval shaped
and not reusable, DO NOT USE THE PART AGAIN.
Table 14
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Determining the Difference from the 3 Measurements Taken
Location Calculations Results
G1 Low Ø 465.705 mm (18.3348 inch)
G2 Mid Ø 465.920 mm (18.3433 inch)
G3 High Ø 466.180 mm (18.3535 inch)
High and Low
G3 - G1 0.475 mm (0.0187 inch)
Difference =
Maximum
Refer to Specifications
Difference 0.47 mm (0.019 inch)
in Table 20.
Allowance
Actual Difference <
Actual Difference = 0.475 mm
Maximum Difference
Actual Difference (H - (0.0187 inch) < than Maximum
Allowance = Fail
L) Maximum Difference Difference Allowance of 0.47 mm
Actual Difference >
Allowance (0.019 inch)
Maximum Difference
Fail
Allowance = Pass
External Spline
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Illustration 52 g06321303
Typical wear step on an external spline.
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Illustration 53 g06322365
Typical example of using a straight edge to measure a wear step on a spline tooth.
If possible, use a straight edge and a feeler gauge to measure questionable spline wear.
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Illustration 54 g01716121
Typical example of a wear step. A 0.152 mm (0.0060 inch) wear step is required to stop a seal pick. If the wear step is
greater than 0.203 mm (0.0080 inch), then DO NOT USE THE PART AGAIN.
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Illustration 55 g06075290
Typical example of taking a Measurement Over Pins (MOP).
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Illustration 56 g06181327
(L) 1, (L) 2, and (L) 3 Measurement Locations
The location of gage pins at 60° intervals is critical to the formula. These three locations will provide
information about the wear of the part. Refer to Illustration 56.
Note: For odd splines take measurement as close to 180° from each gage pin as possible.
Place gage pins at 60° intervals on the spline. Take the measurements over gage pins that are located
approximately 180° away from each other.
A micrometer must be positioned to measure the highest external points on the gage pins. This
procedure will provide the measurement of the wear of the spline. The gage pin diameter for each
individual part is determined by the size and pitch of the spline. Calculate the average from the values
taken. The difference between the measurements will determine if there is an out of round condition
caused by poor load distribution on the splines.
Steps 1 through 4 demonstrate an example of the process to calculation external spline roundness.
Provided is an example of performing spline reusability calculations of a spindle part number
131-1296 for a 990 Series II wheel loader.
NOTICE
The spline must pass the roundness tests by meeting the reusability
specification measurement over gage pins and the maximum difference
between the high and low measurements to be reused again.
1. Take measurements at locations (L) 1, (L) 2, and (L) 3 over gage pins. Taken measurements are
recorded in Table 15.
Table 15
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2. Add the measurements together to calculate the sum. The sum of the three measurements is
896.700 mm (35.3031 inch).
Table 16
990 Series II Wheel Loader Spindle (131-1296) External Spline
Example of Calculating Sum of 3 Measurements Taken
Measurement
Calculation SUM Total =
Locations
L1, L2, and L3 L1 + L2 + L3 896.700 mm (35.3031 inch)
3. Divide the sum of the measurements taken by 3 to calculate the average. The calculated average
of 298.900 mm (11.7677 inch) is greater than the reusability specification of 298.781 mm
(11.7630 inch). In this example the external spline is within the reusability specification and
therefore passes this test, proceed to Step 4.
If the external spline is less than the reusability specification, then DO NOT USE THE PART
AGAIN.
Table 17
990 Series II Wheel Loader Spindle (131-1296) External Spline
Example of Calculating the Average of 3 Measurements Taken
Location Calculations Results
(L1 + L2 + L3) / 3
L1, L2, and L3 Ø 298.900 mm (11.7677 inch)
= Avg
Refer to
Reusability
Specifications in Ø 298.781 mm (11.7630 inch)
Specification
Table 19.
Avg < Reusability Avg = Ø 298.900 mm (11.7677 inch) > than
Specification = Fail Reusability Specification of Ø 298.781 mm
Avg Specification
Avg > Reusability (11.7630 inch)
Specification = Pass Pass
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4. The difference between the high measurement and the low measurement determines if the
spline is round. Out-of-round or ovality can cause uneven load distribution on the splines.
Calculate the difference between the high and the low measurement by subtracting the high
measurement of Ø 299.000 mm (11.7716 inch) from the low measurement of Ø 298.800 mm
(11.7638 inch). The difference between the high and low measurement determine if the spindle
can be reused. The difference in this example is 0.200 mm (0.0079 inch).
Maximum difference between the high measurement and the low measurement allowance of
0.30 mm (0.012 inch) and the actual difference of 0.200 mm (0.0079 inch) is less than the
allowable maximum difference.
If the maximum difference between the high measurement and the low measurement is greater
than 0.30 mm (0.012 inch) the external spline is considered to be out-of-round or oval shaped
and not reusable, DO NOT USE THE PART AGAIN.
Table 18
990 Series II Wheel Loader Spindle (131-1296) External Spline
Example of Determining the Difference from the 3 Measurements Taken
Location Calculations Results
L1 High Ø 299.000 mm (11.7716 inch)
L2 Mid Ø 298.900 mm (11.7677 inch)
L3 Low Ø 298.800 mm (11.7638 inch)
High and Low
L1 - L3 0.200 mm (0.0079 inch)
Difference =
Maximum
Refer to Specifications
Difference 0.30 mm (0.012 inch)
in 19.
Allowance
Actual Difference >
Actual Difference = 0.200 mm
Maximum Difference
Actual Difference (H - (0.0079 inch) < than Maximum
Allowance = Fail
L) Maximum Difference Difference Allowance of 0.30 mm
Actual Difference <
Allowance (0.012 inch)
Maximum Difference
Pass
Allowance = Pass
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Illustration 57 g06075262
Typical example of MOP.
(N) Rubber Band
(P) Gage Pins
Note: Rubber band (N) can be used to secure gage pins (P) in place when taking measurements of
external splines. Refer to Illustration 57.
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Illustration 58 g06124082
Typical example of a magnetizer/ demagnetizer.
NOTICE
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If gage pins are magnetized, then demagnetize after use. When a gage
pin is magnetized, cuttings and iron powder will easily stick to the
surface, thus precipitating wear.
Gage pins can be magnetized to aid in taking measurements between or over gage pins. Ensure that
gage pins are demagnetized after use and stored properly.
View Image
Illustration 59 g06321299
Typical example of taking a Measurement Over Pins (MOP) (A) of spindle spline.
(A) Measurement Over Pins (MOP)
Table 19
Record Actual
Dimensions
Refer to the
"Measurement
Techniques"
Spindle Spline Dimensions and Tolerances (1) section for the
proper
techniques and
number of
measurements
to be taken.
Part Gage Pin Original Reusability Maximum Measurement
Number Diameter Specification Specification Difference
Measurement Measurement
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5V-4062
9C-0615
138-4805
Ø 6.3500 mm Ø 120.881 mm Ø 120.8255 mm 0.0555 mm L1 =
5V-5692
(0.25000 inch) (4.7591 inch) (4.75690 inch) (0.00219 inch)
Ø 3.9675 mm Ø 88.4020 mm Ø 88.3456 mm 0.0564 mm L1 =
6S-3012
(0.15620 inch) (3.48039 inch) (3.47817 inch) (0.00222 inch)
Ø 4.7625 mm Ø 299.080 mm Ø 298.9818 mm 0.0982 mm L1 =
6W-7349
(0.18750 inch) (11.7748 inch) (11.77091 inch) (0.00387 inch)
4.7625 mm L1 =
(0.18750 inch) Ø 169.545 mm Ø 169.4744 mm 0.0706 mm
7K-3737
Ø 4.763 mm (6.6750 inch) (6.67221 inch) (0.00278 inch)
(0.1875 inch)
Ø 6.3500 mm Ø 140.086 mm Ø 140.0267 mm 0.0593 mm L1 =
7U-0774
(0.25000 inch) (5.5152 inch) (5.51285 inch) (0.00234 inch)
7V-8640 Ø 6.3500 mm Ø 124.371 mm Ø 124.3150 mm 0.0560 mm L1 =
9C-2310 (0.25000 inch) (4.8965 inch) (4.89428 inch) (0.00221 inch)
Ø 4.7625 mm Ø 207.6679 mm Ø 207.5892 mm 0.0787 mm L1 =
8K-6574
(0.18750 inch) (8.17589 inch) (8.17279 inch) (0.00310 inch)
Ø 4.7625 mm Ø 169.545 mm Ø 169.4744 mm 0.0706 mm L1 =
8K-6929
(0.18750 inch) (6.6750 inch) (6.67221 inch) (0.00278 inch)
Ø 4.8768 mm Ø 207.9219 mm Ø 207.8434 mm 0.0785 mm L1 =
8S-4173
(0.19200 inch) (8.18589 inch) (8.18279 inch) (0.00309 inch)
Ø 6.3500 mm Ø 140.086 mm Ø 140.0267 mm 0.0593 mm L1 =
8V-6388
(0.25000 inch) (5.5152 inch) (5.51285 inch) (0.00234 inch)
9C-1639 Ø 6.3500 mm Ø 121.008 mm Ø 120.9526 mm 0.0554 mm L1 =
138-4804 (0.25000 inch) (4.7641 inch) (4.76191 inch) (0.00218 inch)
Ø 6.3500 mm Ø 121.0081 mm Ø 120.9527 mm 0.0554 mm
9K-4966 L1 =
(0.25000 inch) (4.76409 inch) (4.76191 inch) (0.00218 inch)
9Q-5379 Ø 4.7630 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
388-4764 (0.18752 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)
Ø 4.762 mm Ø 169.545 mm Ø 169.4744 mm 0.0706 mm
9V-1330 L1 =
(0.1875 inch) (6.6750 inch) (6.67221 inch) (0.00278 inch)
Ø 4.7625 mm Ø 299.080 mm Ø 298.9818 mm 0.0982 mm L1 =
116-6260
(0.18750 inch) (11.7748 inch) (11.77091 inch) (0.00387 inch)
Ø 4.7625 mm Ø 299.080 mm Ø 298.9818 mm 0.0982 mm L1 =
131-1296
(0.18750 inch) (11.7748 inch) (11.77091 inch) (0.00387 inch)
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Illustration 60 g06321308
Typical example of taking a measurement between pins (B) of a reaction hub spline.
(B) Measurement Between Pins
Table 20
Original Reusability
Maximum
Assembly Specification Specification
Part Gage Pin Difference
Part Measurement Measurement
Number Diameter High and Low
Number Between Gage Between Gage
Measurement
Pins Pins
1C-7312 1C-7101
Ø 4.877 mm Ø 154.955 mm Ø 155.0332 mm 0.0782 mm
317-4581 317-4580
(0.1920 inch) (6.1006 inch) (6.10366 inch) (0.00308 inch)
463-9549 463-9547
Ø 6.3500 mm Ø 119.642 mm Ø 119.7143 mm 0.0723 mm
1V-8610 1V-8608
(0.25000 inch) (4.7103 inch) (4.71315 inch) (0.00285 inch)
2V-5711 2V-5712
Ø 6.3500 mm Ø 103.817 mm Ø 103.8876 mm 0.0706 mm
9C-5852 9C-5851
(0.25000 inch) (4.0873 inch) (4.09005 inch) (0.00278 inch)
174-7484 174-7483
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View Image
Illustration 61 g06369821
Typical example of taking a measurement between pins (B) of a reaction hub spline.
Note: Typical example of a reaction hubwithout bearing journal.
(B) Measurement Between Pins
Table 21
Internal Reaction Hub Spline Dimensions and Tolerances (1) Record Actual
Dimensions
Refer to the
"Measurement
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Techniques"
section for the
proper
techniques and
number of
measurements
to be taken.
Original Reusability
Maximum
Specification Specification
Part Gage Pin Difference
Measurement Measurement Measurement
Number Diameter High and Low
Between Gage Between Gage
Measurement
Pins Pins
Ø 5.4864 mm Ø 242.0137 mm Ø 242.1111 mm 0.0974 mm
1V-6273 G1 =
(0.21600 inch) (9.52808 inch) (9.53191 inch) (0.00383 inch)
5D-5452 Ø 4.877 mm Ø 154.955 mm Ø 155.0317 mm 0.07649 mm
G1 =
8D-2091 (0.1920 inch) (6.1006 inch) (6.10360 inch) (0.00301 inch)
Ø 5.4864 mm Ø 465.701 mm Ø 465.8431 mm 0.1421 mm
137-8628 G1 =
(0.21600 inch) (18.3347 inch) (18.34024 inch) (0.00559 inch)
Ø 5.0000 mm Ø 467.1800 mm Ø 467.3218 mm 0.1418 mm
419-6353 G1 =
(0.19685 inch) (18.3929 inch) (18.39846 inch) (0.00558 inch)
(1) Note: The most current part number is identified in bold font when multiple part numbers are in a cell.
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Illustration 62 g06321309
Typical example of taking a Measurement Over Pins (MOP) (C) of a reaction hub spline.
(C) Measurement Over Pins (MOP)
Table 22
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External Reaction Hub Spline Dimensions and Tolerances (1) Record Actual
Dimensions
Refer to the
"Measurement
Techniques"
section for the
proper
techniques and
number of
measurements
to be taken.
Original Reusability
Maximum
Assembly Specification Specification
Part Gage Pin Difference
Part Measurement Measurement Measurement
Number Diameter High and Low
Number Over Gage Over Gage
Measurement
Pins Pins
1C-7101 L1 =
Ø 9.7536 mm Ø 448.719 mm Ø 448.5663 mm 0.1527 mm
— 317-4580
(0.3840 inch) (17.6661 inch) (17.66006 inch) (0.00601 inch)
463-9547
Ø 9.525 mm Ø 405.376 mm Ø 405.2098 mm 0.1662 mm L1 =
1V-8610 1V-8608
(0.3750 inch) (15.9597 inch) (15.95311 inch) (0.00654 inch)
2V-5711 2V-5712 L1 =
Ø 7.9375 mm Ø 359.621 mm Ø 359.4610 mm 0.1600 mm
9C-5852 9C-5851
(0.3125 inch) (14.1583 inch) (14.15198 inch) (0.00630 inch)
174-7484 174-7483
4D-7614 Ø 10.9728 mm Ø 665.594 mm Ø 665.3563 mm 0.2377 mm L1 =
—
6G-6874 (0.4320 inch) (26.2044 inch) (26.19508 inch) (0.00936 inch)
Ø 7.9375 mm Ø 307.848 mm Ø 307.7044 mm 0.1437 mm
4V-0092 175-7527 L1 =
(0.3125 inch) (12.1200 inch) (12.11432 inch) (0.00566 inch)
Ø 9.5250 mm Ø 348.651 mm Ø 348.5246 mm 0.1264 mm
4V-8535 162-9389 L1 =
(0.37500 inch) (13.7264 inch) (13.72141 inch) (0.00498 inch)
Ø 6.3500 mm Ø 273.566 mm Ø 273.4679 mm 0.0981 mm L1 =
4V-9820 4V-9818
(0.25000 inch) (10.7703 inch) (10.76643 inch) (0.00386 inch)
5K-4408 5K-4271 Ø 9.5250 mm Ø 407.3931 mm Ø 407.2342 mm 0.1589 mm L1 =
7K-7462 7K-7463 (0.37500 inch) (16.0391 inch) (16.03281 inch) (0.00626 inch)
5V-4702 L1 =
Ø 14.2875 mm Ø 729.008 mm Ø 728.8048 mm 0.2032 mm
— 5V-8974
(0.56250 inch) (28.7010 inch) (28.69304 inch) (0.00800 inch)
6W-7272
5V-9356 Ø 7.9375 mm Ø 278.488 mm Ø 278.3904 mm 0.0976 mm L1 =
5V-9355
9C-9187 (0.31250 inch) (10.9641 inch) (10.96023 inch) (0.00384 inch)
L1 =
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(1) Note: The most current part number is identified in bold font when multiple part numbers are in a cell.
View Image
Illustration 63 g06369827
Typical example of taking a Measurement Over Pins (MOP) (C) of a reaction hub spline.
Note: Typical example of a reaction hub without bearing journal.
(C) Measurement Between Pins
Table 23
Record Actual
Dimensions
Refer to the
"Measurement
Techniques"
External Reaction Hub Spline Dimensions and Tolerances (1) section for the
proper
techniques and
number of
measurements
to be taken.
Original Reusability
Maximum
Specification Specification
Part Gage Pin Difference
Measurement Measurement Measurement
Number Diameter High and Low
Over Gage Over Gage
Measurement
Pins Pins
Ø 12.7000 mm Ø 725.2513 mm Ø 725.0331 mm 0.2182 mm
1V-6273 L1 =
(0.50000 inch) (28.5532 inch) (28.54455 inch) (0.00859 inch)
5D-5452 Ø 8.7782 mm Ø 575.1043 mm Ø 575.0208 mm 0.0835 mm
L1 =
8D-2091 (0.3456 inch) (22.6419 inch) (22.63857 inch) (0.00329 inch)
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View Image
Illustration 64 g06321257
Typical example of outboard bearing (8) placement variations.
Note: The outboard bearing placement is on the spindle of the final drive wheel group on left versus the hub on the right.
(1) Spindle
(3) Hub
(8) Outboard Bearing
The placement of the outboard wheel bearings can be on the hub or spindle. Inspect the spindle and
hub bearing journals and the bearing bores of the wheel for wear at each rebuild.
NOTICE
If the bearing journal or bore has significant wear, the bearings will fit
loosely and will cause premature failure of the components.
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1. Start with a visual inspect of all bearing journal and bores. Bearing bores and journals can be
inspected with the naked eye. To provide the best results, a magnifying glass and a strong light
source such as sunlight are recommended. Check each component for cracks, bruising,
scratching, or spalling. It can also be difficult to distinguish between small scratches and small
cracks. In these cases, perform Wet Magnetic Particle Testing (MPT) or Liquid Penetrant
Testing (PT), refer to the "Crack Detection Methods" section.
2. After passing visual/ Non-Destructive testing, then measure the bearing journal and bores to
ensure that the component meets the criteria for reusability in Table 24 through Table 26.
3. If any defects are present, DO NOT USE PART until the component is salvaged. The
component can be used after performing the applicable salvage procedure.
The outboard bearings are positioned on the spindle in two different ways. The outboard bearings are
positioned on the spindle, or the hub which is then mounted to the spindle. If the bearing is mounted
to the hub, the spindle should still be checked for wear in locations where contact locations with the
hub. If the spindle has wear characteristics, thermal spray may be used to salvage the spindle. Refer to
the "References" section for applicable information regarding thermal spray. Refer to Table 24 for
part number-specific outer diameter dimensions of spindles.
Note: Refer to the "References" section for applicable information regarding thermal spray.
View Image
Illustration 65 g06320902
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Table 24
Record Actual Dimensions
Refer to the "Measurement Techniq
Spindle Outside Diameter Tolerance (1)
section for the proper techniques and n
of measurements to be taken.
Part Tolerance Tolerance
Measurement Measurement
Number (A) (B)
Ø 165.0822 ± 0.0127 mm Ø 120.6373 ± 0.0127 mm A1 = A2 =
1V-1317
(6.4993 ± 0.0005 inch) (4.7495 ± 0.0005 inch)
1V-1379 Ø 117.462 ± 0.013 mm Ø 104.762 ± 0.013 mm
A1 = A2 =
4K-6388 (4.6245 ± 0.0005 inch) (4.1245 ± 0.0005 inch)
1V-1392 A1 = A2 =
Ø 117.457 ± 0.013 mm Ø 104.762 ± 0.013 mm
2V-5132
(4.6243 ± 0.0005 inch) (4.1245 ± 0.0005 inch)
7K-1138
1V-1554
Ø 95.232 ± 0.013 mm Ø 76.060 ± 0.013 mm
6K-8848 A1 = A2 =
(3.7493 ± 0.0005 inch) (2.9945 ± 0.0005 inch)
7K-7468
1V-4718 A1 = A2 =
Ø 95.232 ± 0.013 mm Ø 82.537 ± 0.013 mm
6K-5836
(3.7493 ± 0.0005 inch) (3.2495 ± 0.0005 inch)
7K-7459
Ø 189.962 ± 0.025 mm Ø 155.423 ± 0.025 mm A1 = A2 =
1V-4975
(7.4788 ± 0.0010 inch) (6.1190 ± 0.001 inch)
Ø 165.085 ± 0.015 mm Ø 123.00 ± 0.013 mm A1 = A2 =
3Q-6136
(6.4994 ± 0.0006 inch) (4.8425 ± 0.0005 inch)
3V-2478 A1 = A2 =
Ø 304.770 ± 0.025 mm Ø 260.320 ± 0.025 mm
5V-7635
(11.9988 ± 0.0010 inch) (10.2488 ± 0.0010 inch)
6W-7271
Ø 95.235 ± 0.015 mm A1 = A2 =
(3.7494 ± 0.0006 inch) Ø 82.537 ± 0.013 mm
3Y-4071
Ø 95.232 ± 0.013 mm (3.2495 ± 0.0005 inch)
(3.7493 ± 0.0005 inch)
Ø 117.460 ± 0.015 mm Ø 104.762 ± 0.013 mm A1 = A2 =
3Y-5779
(4.62440 ± 0.0006 inch) (4.1245 ± 0.0005 inch)
3Y-7724 A1 = A2 =
Ø 95.235 ± 0.015 mm Ø 76.060 ± 0.013 mm
4V-9580
(3.7494 ± 0.0006 inch) (2.9945 ± 0.0005 inch)
9C-2312
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Note: Refer to the "References" section for applicable information regarding thermal spray.
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View Image
Illustration 66 g06320923
Typical example of a reaction hub.
(C) Bearing Journal
The reaction hub shown in Illustration 66 is designed with a bearing journal (C). When inspecting this
design, the hub and the spindle should be inspected and measured. The hub must meet specifications
for new parts and the hub must have no abrasive wear or adhesive wear. If the reaction hub does not
meet the required conditions, the hub can be reworked by use of thermal spray and machining. Refer
to Table 25 for tolerances of reaction hub bearing journal.
Table 25
Record Actual Dimensions
Refer to the "Measurement Techniques"
Reaction Hub Bearing Journal Tolerances (1)
section for the proper techniques and number
of measurements to be taken.
Assembly
Part Tolerance
Part Measurement Measurement Measurement
Number (C)
Number
1C-7312 1C-7101 C1 = C2 = C3 =
Ø 203.3 ± 0.025 mm
317-4581 317-4580
(8.00 ± 0.0010 inch)
463-9549 463-9547
Ø 165.085 ± 0.015 mm C1 = C2 = C3 =
1V-8610 1V-8608
(6.4994 ± 0.0006 inch)
2V-5711 2V-5712 C1 = C2 = C3 =
Ø 146.035 ± 0.015 mm
9C-5852 9C-5851
(5.7494 ± 0.0006 inch)
174-7484 174-7483
— C1 = C2 = C3 =
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Ø 206.375 ± 0.015 mm
(8.125 ± 0.0006 inch)
Ø 206.375 ± 0.015 mm C1 = C2 = C3 =
110-0552 105-8715
(8.125 ± 0.0006 inch)
Ø 385.862 ± 0.025 mm C1 = C2 = C3 =
— 107-0691
(15.1914 ± 0.001 inch)
118-9399 118-9400 Ø 206.375 ± 0.025 mm C1 = C2 = C3 =
162-0193 162-0194 (8.125 ± 0.0010 inch)
Ø 237.43 ± 0.025 mm C1 = C2 = C3 =
137-8846 137-8847
(9.3476 ± 0.001 inch)
Ø 206.375 ± 0.025 mm C1 = C2 = C3 =
162-0268 162-0269
(8.125 ± 0.0010 inch)
Ø 457.3 ± 0.025 mm C1 = C2 = C3 =
— 244-1096
(18.00 ± 0.0010 inch)
170.05 ± 0.015 mm
317-1300 317-1299 C1 = C2 = C3 =
(6.695 ± 0.0006 inch)
(1) Note: The most current part number is identified in bold font when multiple part numbers are in a cell.
Determine the maximum allowable wear of the bore of the bearing cup of the wheel assembly with
the following procedure:
1. Measure the Inside Diameter (ID) of the bearing bores of the wheel. Refer to the "Measurement
Techniques" section.
3. If there is significant wear or the bore is not within the specifications, the wheel must be
replaced or salvaged. To salvage the bore of the wheel, refer to the "References" section for
applicable thermal spray options.
View Image
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Illustration 67 g06321589
Typical example of a wheel.
(D) Inboard Bearing Bore
(E) Outboard Bearing Bore
Table 26
Refer to th
Wheel Bearing Bore Tolerances (1)
section for the
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5K-4703
6K-8935
7K-3423
Ø 149.912 ± 0.035 mm Ø 158.687 ± 0.035 mm A1 =
— 5V-9357
(5.9020 ± 0.0014 inch) (6.2475 ± 0.0014 inch)
6K-5832 6K-5840 Ø 152.35 ± 0.03 mm Ø 180.92 ± 0.03 mm
A1 =
8K-8269 8K-8242 (5.998 ± 0.001 inch) (7.123 ± 0.001 inch)
Ø 149.94 ± 0.03 mm Ø 158.70 ± 0.03 mm A1 =
6S-3020 6S-3010
(5.903 ± 0.001 inch) (6.248 ± 0.001 inch)
Ø 259.892 + 0.040 - 0.080 mm Ø 239.907 + 0.035 - 0.070 mm A1 =
— 7V-0592
(10.2320 + 0.0016 - 0.0032 inch) (9.4451 + 0.0014 - 0.0028 inch)
Ø 193.62 ± 0.03 mm Ø 180.98 ± 0.03 mm A1 =
8K-6846 8K-6295
(7.623 ± 0.001 inch) (7.125 ± 0.001 inch)
Ø 314.2742 ± 0.0381 mm Ø 282.5242 ± 0.0381 mm A1 =
8K-6556 8K-6559
(12.3730 ± 0.0015 inch) (11.1230 ± 0.0015 inch)
Ø 266.6492 ± 0.0381 mm Ø 247.5992 ± 0.0381 mm A1 =
8K-8143 8K-8116
(10.4980 ± 0.0015 inch) (9.7480 ± 0.0015 inch)
Ø 266.6492 ± 0.0381 mm Ø 247.5992 ± 0.0381 mm A1 =
— 8K-8796
(10.4980 ± 0.0015 inch) (9.7480 ± 0.0015 inch)
Ø 190.437 ± 0.035 mm Ø 193.612 ± 0.035 mm
— 8R-4087 A1 =
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
8V-6392 8V-6391 Ø 190.436 ± 0.035 mm Ø 193.611 ± 0.035 mm A1 =
— 103-5961 (7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
9C-1638 Ø 179.936 ± 0.035 mm Ø 193.612 ± 0.035 mm A1 =
—
9C-4597 (7.0841 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 136.465 ± 0.035 mm Ø 148.370 ± 0.035 mm A1 =
— 9C-3920
(5.3726 ± 0.0014 inch) (5.8413 ± 0.0014 inch)
Ø 182.4990 ± 0.0356 mm Ø 193.6115 ± 0.0355 mm A1 =
9K-1174 9K-1173
(7.1850 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm
9K-4103 9K-4104 A1 =
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm
9K-4254 8K-6930 A1 =
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm A1 =
— 9K-4822
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm A1 =
— 9K-4829
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
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NOTICE
Regardless of which crack detection method is used, it is important
that the instructions furnished with the detection equipment are
followed closely when checking any component. Failure to do so may
cause inaccurate results or may cause injury to the operator and/or
surroundings.
There are five major crack detection methods or Non-Destructive Testing (NDT) listed in this section:
Visual Surface Inspection (VT), Liquid Penetrant Testing (PT), Dry / Wet Magnetic Particle Testing
(MPT), and Ultrasonic Testing (UT).
Crack detection methods or NDT is methods for testing components for cracks without damaging the
component. VT, PT, Dry/ Wet MPT, and UT are methods recommended. There may be more than
one acceptable crack detection method for the testing of a given part, although PT is the most
versatile. For example, the PT method can be used when testing smooth machined components such
as shafts, gear teeth, and splines, but using the Wet MPT is more accurate. Refer to Table 27 for
advantages and disadvantages and Table 28 for standards and requirements for these NDT methods.
Table 27
Crack Detection Methods Advantages vs. Disadvantages
Detection
Advantages Disadvantages
Method
- Least Expensive
- Limited to surface-only defects.
- Detects most damaging
Visual Surface - Requires inspectors to have broad knowledge
defects.
Inspection (VT) of welding and fabrication in addition to Non-
- Immediate Results
Destructive Testing (NDT).
- Minimum part preparation
Liquid Penetrant - Inexpensive - Least Sensitive
Testing (PT) - Minimal Training - Detects surface cracks only.
- Portable - Rough or porous surfaces interfere with test
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- Works on nonmagnetic
material.
- Portable
- Works on magnetic material only.
Dry Magnetic - Fast/Immediate Results
- Less sensitive than Wet Magnetic Particle
Particle (MPT) - Detects surface and
Testing (MPT).
subsurface discontinuities
- More sensitive than Liquid
- Requires power for light.
Penetrant Testing (PT).
Wet Magnetic - Works on magnetic material only.
- Detects subsurface as
Particle (MPT) - Liquid composition and agitation must be
much as 0.13 mm
monitored.
(0.005 inch).
- Most Sensitive
- Detects deep material
defects. - Most Expensive
Ultrasonic
- Immediate Results - Requires operator training and certification.
Testing (UT)
- Wide range of materials - Surface must be accessible to probe
and thickness can be
inspected
Table 28
Applicable Crack Detection Standards
Minimum
Acceptance Required
Detection Method Standard
Criteria Personnel
Qualifications
EN-ISO 9712
Visual Surface EN-ISO 5817 EN-ISO 5817 - Level B
ANSI-ASNT SNT-
Inspection (VT) AWS D1.1 AWS D1.1 - Table 6.1
TC-1A
EN-ISO 9712
Liquid Penetrant EN-ISO 3452 EN-ISO 23277
ANSI-ASNT SNT-
Testing (PT) ASTM E165 AWS - D1.1
TC-1A
EN-ISO 9712
Magnetic Particle EN-ISO 17638 EN-ISO 23278 - Level 1
ANSI-ASNT SNT-
Testing (MPT) ASTM E709 AWS D1.1 - Table 6.1
TC-1A
EN-ISO 11666 Technique
EN-ISO 17640 - EN-ISO 9712
Ultrasonic Testing 2 - Level 2
Level B ANSI-ASNT SNT-
(UT) AWS D1.1 - Class A -
AWS D1.1 TC-1A
Table 6.3
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Illustration 68 g06124166
Example of Visual Surface Inspection (VT) Tooling
(A) Flashlight (or adequate light source)
(B) Magnifying Glass
(C) Tape Measure (or other measuring device)
(D) Inspection Mirror
Components and welds that are to be tested using PT, MPT, or UT shall first be subject to a Visual
Surface Inspection (VT). VT is often the most cost-effective inspection method and requires little
equipment as seen in Illustration 75. Personnel performing VT shall either be trained to a company
standard or have sufficient experience and knowledge regarding the components being inspected.
Personnel performing VT shall take routine eye exams.
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.
• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to
wipe the surface clean.
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• Penetration Oil: 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 penetrating oil indications.
• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
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Illustration 69 g06084048
Typical example of pre-cleaning the testing area.
1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil.
Wipe the area to be tested with a solvent dampened cloth to remove remaining dirt and allow
the area to dry. Remove paint where there are visible cracks using paint remover or a wire
brush.
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Illustration 70 g06084053
Typical example of applying penetrating oil to areas to be tested.
2. Apply penetrating oil by spraying to the entire area to be tested. Allow 10 to 15 minutes for
penetrating oil to soak. After the penetrating oil has been allowed to soak, remove the excess
penetrating oil with clean, dry wipe.
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Illustration 71 g06084060
Typical example of removing penetrating oil with a cloth.
3. The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or
wipe. Allow the area to dry thoroughly.
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Illustration 72 g06084070
Typical example of applying the developer.
4. Before using developer, ensure that the developer is mixed thoroughly by shaking the container.
Hold the container approximately 203 - 305 mm (8 - 12 inch) away from part. Apply an even,
thin layer of developer over the area being tested. A few thin layers are a better application
method than one thick layer.
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Illustration 73 g03773759
Typical example of cracks found during Liquid Penetrant Testing (PT).
5. Allow the developer to dry completely for 10 to 15 minutes before inspecting for cracks.
Defects will show as red lines in white developer background, refer to Illustration 73. Clean the
area of application of the developer with solvent cleaner.
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Illustration 74 g06085930
(A) Indications shown by Dry Magnetic Particle Testing (MPT).
(B) 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.
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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 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.
Illustration 75 g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MPT).
(B) Electromagnetic Yoke
(D) Ultraviolet Lamp
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Illustration 76 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:
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) divisions,
refer to Illustration 76. 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 5 mm2/s (5 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:
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◾ Low viscosity shall not exceed a maximum viscosity of 5 mm2/s (5 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 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).
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.
View Image
Illustration 77 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 77 for an
example of yoke placement.
Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be
consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can
be detected by an experienced technician. Refer to Table 28 for crack detection standards.
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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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