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Reuse And Salvage Guidelines

Salvage Procedure for Final Drive Planet Gear Used in Off-Highway Trucks{4050,
4055}
Media Number -SEBF8185-05 Publication Date -17/06/2013 Date Updated -17/06/2013

i05366214

Salvage Procedure for Final Drive Planet Gear Used in Off-

Highway Trucks{4050, 4055}
SMCS - 4050; 4055

Off-Highway Truck/Tractor:
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)

Introduction
Table 1
Revision
Summary of Changes in SEBF8185

05 Changed group effectivity to individual and added Metal Spray Guidelines.

Updated introduction, replaced SERF8799 with SERF8473 and SERF8704, and
04
updated group effectivity.
Updated introduction, added Canceled Part Numbers section, reviewed media (updated
03
title for SEBF8093, corrected SERF8779 to SERF8799), and part numbers.

© 2013 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.

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This Reuse and Salvage Guideline contains the necessary information in order 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 in order 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 questions or additional information concerning this guideline, submit a form for feedback in the
Service Information System. In order to address an urgent issue, use the following resources in order
to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for
information about canceled part numbers and replaced part numbers. NPR will provide the current
part numbers for replaced parts.

Important Safety Information

Illustration 1 g02139237

Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are
caused by failure to observe safety warnings. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. Personnel must be properly trained in order
to perform maintenance, repair, or operate any machine. Safety precautions and warnings are

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provided this instruction and on Caterpillar products. These warnings should be observed before
performing any procedures. Caterpillar cannot anticipate every possible circumstance that might
involve a potential hazard. The warnings in this publication and on the product are not all inclusive.

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 in
Illustration 2.

Illustration 2 g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your Safety is Involved.

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
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
First reduction planet gears in the final drives for 789 Off-highway Trucks some times experience ID
(inside diameter) damage. This damage is caused when the bearing cup of the 6Y-0663 Bearing
Assembly rotates inside the bore. An engineering change in all newly released parts has been made to
increase the press fit between the bearing cup and the inside bore of the gear. This guideline provides
the method and specifications to rework gears to the new engineering specifications.

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Final drive gears that meet the reuse/salvage specifications can be expected to perform normally in
the same application until the next overhaul. Never install a part that this Guideline indicated cannot
be used again. Before installing a used or reconditioned part, correct any conditions that may have
caused the original wear.

References
ReferenceReuse and Salvage Guidelines, SEBF8093, "Planetary Final Drives for Wheel Loaders,
Wheel Tractors, and Compactors"

ReferenceReuse and Salvage Guidelines, SEBF8193, "Reusability of Drive Train Gears"

Equipment and Tooling

The list of machines and tooling is a recommended list. The salvage procedure can also be completed
using equivalent machinery.

Table 2
Equipment and Tooling
Part Number Description
- Lathe with a 12 inch swing
- Metro metal spray equipment
- Die Grinder
6V-4087 Holder
4C-3868 Polishing Disc
8T-5096 Dial Indicator Test Group
- Insert Tool Holder and C-2 grade Carbide Inserts
- Inside Micrometers
- Grit Blaster - Dedicated for metal spray only

Visual Inspection

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Illustration 3 g02151376

Use Again Only after reworking the gear according to the salvage procedure.

The bore of the gear is scored due to the bearing cup spinning inside the bore. This is unacceptable for
reuse before the salvage procedure has been performed.

Illustration 4 g02152251

Use Again Only after reworking the gear according to the salvage procedure.

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The inside bore of the gear is scored from the removal of the bearing cup. This damaged area is
located between the arrows. The other damage that can be seen is caused by the bearing cup spinning
inside the bore.

Preparing Gears For Salvage

Gear Cleaning Procedure

Use a 4C-3868 Polishing Disc on a Die Grinder to remove the discoloration and scoring from the ID.
When the cleaning process is done correctly, minimal stock will be removed, and the bore will appear
polished.

1. During cleaning, pressure should be exerted evenly to assure uniform stock removal. Clamping
the gear into the chuck of the lathe or onto a rotating table can help assure uniform cleaning and
stock removal.

2. Once the bore is clean, use the grit blaster to prepare the bore surface prior to metal spraying.
Refer to Reuse and Salvage Guidelines, SEBF9236, "Fundamentals of HVOF Spray for
Reconditioning Components", Reuse and Salvage Guidelines, SEBF9238, "Fundamentals of
Arc Spray for Reconditioning Components" and Reuse and Salvage Guidelines, SEBF9240,
"Fundamentals of Flame Spray for Reconditioning Components"for the type of metal spray
suited for this procedure.

Illustration 5 g02153044

The bore has been cleaned and buffed with a 4C-3868 Polishing Disc .

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Measuring the Bore

NOTICE

Do not touch the cleaned and grit blasted bore. Contaminants

deposited from handling can affect the bond strength of metal spray
coating and contribute to future failure of the gear.

Use an inside micrometer to measure the bore. The size of the bore should measure 136.436 ± 0.013
mm (5.37149 ± 0.00051 inch). Any gear that is to be used again must meet the reusability criteria in
Reuse and Salvage Guidelines, SEBF8093, "Planetary Final Drives for Wheel Loaders, Wheel
Tractors, and Compactors".

1. If the measurement of the bore is within tolerance, reuse the gear. The chamfer should be1.5 ±
0.5 mm (0.06 ± 0.02 inch) x 45 degrees.

2. If the measurement of the bore measures larger than specified and meets the reuse criteria,
continue with the salvage procedure. If the gear does not meet all the specifications of the
guidelines, Do not Reuse.

Salvage Procedure
1. After the bore is cleaned and grit blasted, for metal spray applications, apply metal spray to the
bore of the planet gear. Depending on the size of the bore, apply approximately 0.25 mm
(0.010) of metal spray material per side.

2. After metal spraying, chuck the gear into the lathe. Use 8T-5096 Dial Indicator Test Group to
adjust TIR (total indicator runout) and to center the OD (outside diameter) of the gear to within
0.13 mm (0.005 inch) or less. See Illustration 4.

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Illustration 6 g02153085

Gear located in the lathe after centering.

Finish Procedure
1. Use a boring bar with a C-2 carbide insert to machine the bore as shown in Illustration 5. The
size of the bore should measure 136.436 ± 0.013 mm (5.3715 ± 0.0005 inch). The chamfer
should measure 1.5 ± 0.5 mm (0.05906 ± 0.01969 inch) x 45 degrees.

2. Follow the metal spray guidelines for the post-coating treatment prior to assembling the bearing
cup into the bore.

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Illustration 7 g02153193

Bore of the gear has been finish machined.

Copyright 1993 - 2022 Caterpillar Inc. Tue Jul 26 08:01:35 MST 2022 
All Rights Reserved.
Private Network For SIS Licensees.

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