Guia de reusabilidad de diferencial

8/9/2019 Guia de reusabilidad de diferencial

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Bienvenido: r080hem

Producto: WHEEL LOADER

Modelo: 972H WHEEL LOADER NPE

Configuración: 972H Weel Loader NPE!!!!"#$P %MACH&NE' POWERED () C"* Engine

Pautas de reutilización y recuperaciónDifferential Housing Components for Wheel Loaders, Articulated Trucks, WheelTractors, Compactors, ntegrated Toolcarriers, and !otor "raders#$%&', $%'()

*+mero de medio -./0'11212 0echa de pu3licación %45145%41( 0echa de actualización %45145%41(

Caterpillar6 Confidential 7ello8

i!+,,!"72

Differential Housing Components for Wheel Loaders,Articulated Trucks, Wheel Tractors, Compactors, Integrated

Toolcarriers, and Motor Graders{!"#, !#$%

&MC& ' 3258; 3284

Integrated Toolcarrier( AllWheel Loader( AllArticulated Truck(

)!" *&+( A-./'012

)3 *&+( AG-/'012)3C *&+( L--/'014 T--/'012

)3C 565CT78 *&+( L-H/'014 T-H/'012)" *&+( AW8/'012

)"9 *&+( L$D/'014 T$1/'012)$3 *&+( A.M/'012)$39 *&+( L$5/'014 T$8/'012

)$39 565CT78 *&+( L$-/'014 T$&/'012D!3D *&+( :MG/'012

D!"39 *&+( "WD/'012D!"3D *&+( ;G/'012

D!"35 &eries ! *&+( $1&/'012D!"35 *&+( "T/'012D!"C *&+( :<C/'012

D!"D *&+( /H=/'012D339 *&+( $&D/'012

D33D *&+( "MG/'012

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D300E Series 2 (S/N: 5KS1-UP)

D30C (S/N: 7ZC1-UP)

D30D (S/N: 3AJ1-UP)D35-HP (S/N: 3FD1-UP)

D350C (S/N: 8XC1-UP)

D35C (S/N: 2D1-UP)

D!00 (S/N: 1"D1-UP)

D!00D (S/N: 8#F1-UP)D!00E Series 2 (S/N: 8PS1-UP)

D!00E (S/N: 2$%1-UP)D!0D (S/N: 2JJ1-UP)

D!!& (S/N: 8SD1-UP)

D550& (S/N: 5ND1-UP)

'*+i,, C.r:81 (S/N: 57U1-UP)

81& (S/N: 15Z1-UP)

81F (S/N: 5FN1-UP &"%1-UP)82& (S/N: 58U1-UP)

82C (S/N: 87X1-UP)82 Series 2 (S/N: A$H1-UP)

82 (S/N: 7'N1-UP)83 (S/N: &%'1-UP 7"Z1-UP)

Si, C.r:

815 (S/N: 41P1-UP 15%1-UP)815& (S/N: 17Z1-UP)

815F (S/N: &K'1-UP 1N1-UP)

825& (S/N: !3N1-UP)825C (S/N: 8X1-UP)

825 Series 2 (S/N: AX&1-UP)

825 (S/N: %N1-UP)

835 (S/N: !!N1-UP)"r r*er:

2!" (S/N: &4K1-UP &431-UP)

6ee, Der:81! (S/N: 40P1-UP 1!%1-UP)

81!& (S/N: 1Z1-UP)

81!F (S/N: &F1-UP 4D"1-UP)

82! (S/N: 241-UP)82!& (S/N: 3H1-UP)

82!C (S/N: 85X1-UP)

82! Series 2 (S/N: A1-UP)

82! (S/N: !SN1-UP)83! (S/N: !3E1-UP)

83!& (S/N: 7&%1-UP 42Z1-UP)

83! (S/N: &PC1-UP Z1-UP)8!! (S/N: &&N1-UP 2KZ1-UP)

8!!H (S/N: &#1-UP)

85! (S/N: A"P1-UP A!1-UP 1J1-UP)85!K (S/N: H4K1-UP H8"1-UP 2211-UP)

6ee, #rr-Srer:

11 (S/N: SZ1-UP)





613 (S/N: 71M1-UP)

613B (S/N: 38W1-UP)

613C Series 2 (S/N: 8LJ1-UP)613C (S/N: 92X1-UP)

613G (S/N: ESB1-UP)

615 (S/N: 6!1-UP)

615C Series 2 (S/N: 9XG1-UP)

615C (S/N: 5"#1-UP)621 (S/N: 2$B1-UP% 23&1-UP)

621B (S/N: 7'C1-UP% 8&C1-UP% 5P1-UP% 351-UP)621E (S/N: 6B1-UP% 6BB1-UP% 2P$1-UP% 2"#1-UP)

621# (S/N: S'1-UP% 8PL1-UP)

621G (S/N: 'L'1-UP% LP1-UP% 'JW1-UP)

621& (S/N: $B'1-UP% N**1-UP% E!1-UP)621+ (S/N: 12*1-UP)

621S (S/N: 8'$1-UP)

623 (S/N: 52U1-UP)623B (S/N: 6P1-UP)

623E (S/N: 6CB1-UP% 6*#1-UP)623# (S/N: 6B'1-UP% 5EW1-UP)

623G (S/N: +W1-UP)623& (S/N: EJ$1-UP% $B#1-UP)

627 (S/N: 5'1-UP% 68M1-UP)

627B (S/N: 1S1-UP% 31-UP% 561-UP)627E (S/N: 6EB1-UP% 6GB1-UP% 7CG1-UP)

627# (S/N: 1$L1-UP)

627G (S/N: X#1-UP)627& (S/N: LC"1-UP% $BW1-UP)

631C (S/N: 67M1-UP)

631$ (S/N: 2W1-UP)

631E Series 2 (S/N: 1B1-UP% 1NB1-UP% 3N$1-UP)631G (S/N: $#1-UP% W'1-UP% CL+1-UP)

633C (S/N: 66M1-UP)

633$ (S/N: 25W1-UP)633E Series 2 (S/N: 2PS1-UP)

637 (S/N: 65M1-UP% 79P1-UP)

637$ (S/N: 26W1-UP% 27W1-UP% 71W1-UP)

637E Series 2 (S/N: 1#B1-UP)637E (S/N: 1JB1-UP)

637G (S/N: X"1-UP)

639$ (S/N: 99X1-UP)

61 (S/N: 6#1-UP% 1M1-UP)61B (S/N: 65'1-UP)

65,B (S/N: 58'1-UP)

651 (S/N: 33G1-UP% M1-UP)651B (S/N: 67'1-UP)

651E (S/N: *+1-UP% 89!1-UP)

657B (S/N: 68'1-UP)657E (S/N: 5*+1-UP% 6"+1-UP% 9,!1-UP% 91!1-UP)

66,B (S/N: 58'1-UP)

666 (S/N: 6&1-UP)





666B (S/N: 66K1-UP)

Introduction

© 2014 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.Unauthorized use of this docuent or the proprietary processes therein !ithout perission ay "e

violation of intellectual property la!. Information contained in this document is consideredCaterpiar: Confidentia !eo"#

This Reuse and #alvage $uideline contains the necessary inforation in order to allo! a dealer toesta"lish a parts reusa"ility progra. Reuse and salvage inforation ena"les Caterpillar dealers andcustoers to "enefit fro cost reductions. %very effort has "een ade in order to provide the ostcurrent inforation that is &no!n to Caterpillar. Continuing iproveent and advanceent of product design ight have caused changes to your product !hich are not included in this pu"lication.This Reuse and #alvage $uideline ust "e used !ith the latest technical inforation that is availa"lefro Caterpillar.

'or (uestions or additional inforation concerning this guideline) su"it a for for feed"ac& in the

#ervice *nforation #yste. *n order to address an urgent issue) use the follo!ing resources in orderto counicate your re(uest to Caterpillar Repair +rocess %ngineering,

- Caterpillar ealer Technical Counicator

- ealer #olution /et!or&

- Caterpillar Technical Representative

- no!ledge /et!or&

Ta"le 1

$e%ision Summar& of Chan'es in SB*11+

1 Added ultiple part nu"ers.

1 Added serial nu"ers 35) 65) ##A) and +C7.

18 Reoved effectivity for 9:T

Canceed Part Num,ers and $epaced Part Num,ers

This docuent ay include canceled part nu"ers and replaced part nu"ers. Use /+R on #*# forinforation a"out canceled part nu"ers and replaced part nu"ers. /+R !ill provide the current part nu"ers for replaced parts.

Summar&

The contents of this guideline discuss the reusa"ility of coponents of the differential housing for

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guidelines. Contact Caterpillar Repair Process Engineering if you need dimensional information for acomponent that is not yet available or if the information is incorrect for your machine. Examples ofgear wear are provided in this publication, but much more detailed description and information foranalysis can be found in publication Reuse and Salvage Guideline, SE!"#$%, &Reusability of 'rive(rain Gears&. )n up*to*date listing of Reuse and Salvage Guidelines is maintained in the Service+nformation System.

References

(able

References

Media Number and Title

Reuse and Salvage Guideline, SE!"#$%, &Reusability of 'rive (rain Gears&

Reuse and Salvage Guideline, SE!"-, &Salvage of 'ifferential ousing )ssembly used on -"/,-"$, and -$% 0ff*ighway (ruc1s&

Reuse and Salvage Guideline, SE!"-", &Specifications for +nspection of 'riveline !asteners&

'ealer Service (ool Catalog, 2E2G/33, &CS(G (ool and Shop Products Guide 4includes C'5&

Tooling and Equipment

(able %

Required Tools

Part Number Part Number

* E6uipment for Cleaning Components

* E6uipment for Chec1ing Crac1s

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#9*;"/- )brasive :aterial

#9*;"/" )brasive :aterial

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Important Safety Information

Illustration 1 g02139237

Follow all safety warnings. Most accidents that involve product operation, aintenance, or repair arecaused !y failure to o!serve safety warnings. "n accident can often !e avoided !y recogni#ing potentially ha#ardous situations !efore an accident occurs. $ersonnel ust !e properly trained in orderto perfor aintenance, repair, or operate any achine. %afety precautions and warnings are provided this instruction and on &aterpillar products. 'hese warnings should !e o!served !efore perforing any procedures. &aterpillar cannot anticipate every possi!le circustance that ightinvolve a potential ha#ard. 'he warnings in this pu!lication and on the product are not all inclusive.

'he ha#ards are identified !y the (%afety "lert %y!ol( which is followed !y a (%ignal )ord( suchas (*"+-(, ()"+I+( or (&"/'I+(. 'he ()"+I+( %afety "lert %y!ol is shown in

Illustration 2.


'his safety alert sy!ol eans

$ay "ttention4

5ecoe "lert4

6our %afety is Involved.

'he essage that appears under the safety alert sy!ol eplains the ha#ard.

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Operations that may cause product damage are identified by "NOTICE" labels on the product and inthis 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 aresafe. Determine that the operation, lubrication, maintenance, and repair procedures will not

damage the machine. Also, determine that the operation, lubrication, maintenance, and repairprocedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based oninformation which was aailable at the time of publication. The specifications, tor!ues, pressures,measurements, adustments, illustrations, and other items can change at any time. These changes canaffect the serice that is gien to the product. Obtain the complete, most current information beforeyou start any ob. Caterpillar dealers can supply the most current information.

afety

Do not operate or work on this product unless you have read andunderstand the instructions and warnings in the !peration and

"aintenance "anual. #ailure to follow the instructions or heed thewarnings could result in in$ury or death. Contact any Caterpillar dealer

for replacement manuals. %roper care is your responsibility.

&ot oil and components can cause personal in$ury.

Do not allow hot oil or components to contact skin.

Always use a board or cardboard when checking for a leak. 'scapingfluid under pressure, even a pin hole leak, can penetrate body tissue,

causing serious in$ury and possible death. (f fluid is in$ected into your

of in$ury.

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Cleaning

All components need thoroughly cleaned prior to inspection in order to be sure that no damage ishidden by oil or dirt. Use a wash tank or a coarse bristle brush with a mild petroleum-based solvent.

Be sure that the solvent does not have any water contamination. Also, never use a chlorinated solvent.Water or chlorine can cause corrosion on the surface from pitting. Pits cause areas of highlyconcentrated stress that are called stress raisers to occur. hese areas are more likely to result incomponent failure.

!ne good solvent for cabinet washers and hot tanks is "ydrosolv #$$%, which is a strong alkalinecleaner that will not damage aluminum parts. "ydrosolv #$$% is available from &'& in ( gal. and(( gal. containers.

he 8S-2257 )ye *oupe As and 5P-1720 'eal Pick are useful in the close inspection of irregularitieson the surface of the component. Use a dye penetrant or other suitable e+uipment to check allcomponents for cracks, and scrap any cracked parts. )mery cloth or abrasive sheets are used in order

to remove surface rust, light fretting, or nicks from handling. When inspection is completed, be sureto maintain the cleanliness of all acceptable differential components and protect the components frommoisture. f necessary, clean the parts again before reassembly.

NOTICE

Regardless of which crac de!ec!ion "e!hod is #sed$ i! is i"%or!an!!ha! !he ins!r#c!ions f#rnished wi!h !he de!ec!ion e&#i%"en! are

followed closel' when checing an' %ar!s( )ail#re !o do so "a' ca#se

inacc#ra!e res#l!s( *eca#se of high o%era!ing s!resses in differen!ialco"%onen!s$ an' cracs are liel' !o grow and res#l! in fail#re(

Ring +ear and Pinion

!n most machines, the ring and the pinion are serviced separately. "owever, if the ring and the pinionare a matched set, damage to either gear re+uires the installation of a new set.

Pi!!ing of !he Tee!h

S!ar! of ,c!ie Profile

f pitting of the teeth occurs on the ring gear and the pinion, the result is normally a line of small pitsat the 'AP 'tart of Active Profile. he pitting starts first on the pinion, and then on the ring gear.'ee llustration # through llustration /.

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llustration : g%$2:#3$(

Profile of gear tooth

$ 'tart of Active Profile 'AP

2 Pitch line

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llustration # g%$:/:1#2

'light indication of pitting at the 'AP.

Use the gear again.

llustration ( g%$:/34/3

'light indication of pitting at the 'AP.

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Use the gear again.


Slight indication of pitting at the SAP.

Use the gear again.

Pitch Line

Do not reuse gears with an pitting around the pitch line.

Sensor Gear

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Differential Spider Gears, Side Gears, and Pinions

Surfaces of the thrust face must be free of smearing, grooves, corrosion from pitting and any othermechanical damage that could act as a cutting edge against the bearing

Illustration 8 g0123!7"#

$he thrust face has shallo% grooves

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Do not use the gear again.

Illustration # g0123!768

Stains from rusting

Use the gear again.

&art can be reused after removing the rust %ith a fine abrasive cloth

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The thrust face has been grooved by abrasive particles.



The thrust face has been pitted by corrosion.


Spider Shaft

No ear is per!itted on spider shafts.

Differential Housing

Mounting Faces

"ove!ent beteen the halves of the differential housing and beteen the ring gear and the housingcauses the pieces to fret. #retting refers to the earing and transferring of !etal beteen the pieces.$ny parts that sho fretting up to the a!ount in Illustration 12 can be reused after all high spots arere!oved. #ace off the surface and build up the surface by ther!al spray if the da!age is deeper.%ontact dealer support for di!ensions for given parts.

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The damage from fretting on the mounting surface is not excessive. The damage from fretting on the mounting surfacemust not be more than the amount of damage that is shown here.

Use the differential housing again.

Bore of the Spider Shaft

ome fretting is !ermitted in this bore. ee Illustration 13 for a t"!ical exam!le of acce!table fretting.The bores which are machined in the mounting faces of the case ma" show fretting or wear be"ondthis !oint. The bores ma" then be built u! using thermal s!ra" and rebored. This is done together withthe mounting faces. #all $ealer u!!ort in order to obtain this dimension for given housings.

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Typical example of acceptable fretting.


Side Gear and Pinion Thrust Faces

Do not reuse a housing if the thrust bearing has worn into the housing more than 0. mm !0.02 inch".#ee Illustration 14. #urfaces that are worn beyon$ the maximum amount can be sal%age$ with metal

spray or wel$ing proce$ures.

Illustration 14 g013&'('1

The thrust face $oes not ha%e more than 0. mm !0.02 inch" wear.

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The component is acceptable to be reused if the thrust face does not have more than 0.5 mm (0.02inch) of wear.

Locating Dowel for the Thrust Bearing

Do not reuse a housing if the locating dowel is loose. See Illustration 5. !oose dowels will brea"during operation# which will permit the thrust bearing to turn. $ousings with worn dowel holes can besalvaged b% drilling a new hole in the other half of the housing or b% boring the worn hole# pluggingthe hole with a steel rod# and drilling a new hole in the original location.

Illustration 5 g02&'55

$ousing with loose locating dowel.


The hole for the locating dowel must be relocated or repaired in order to be reused.

Support Bearing Journals

The maimum amount of wear that is permitted on the outside diameter of the bearing *ournals thatsupport the differential housing is shown in Table '. +ournals that are worn be%ond this amount can besalvaged with metal spra% or b% sleeving. ,earings that will be used on *ournals that are smaller thanthe new diameter must be installed using 7M-745

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(0.00 inch) can be built up with welding or thermal spra% and can be re4machined to the originaldimensions that are provided in the charts.

Illustration = g02&'5

3cessive wear on the bearing *ournal that supports the differential housing.


The bearing *ournal that supports the differential housing must be repaired.

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Typical group for the differential housing.

(3) lange

(4) !earing "ournal on the plain end

(#) !earing "ournal on the flange end

Ta$le 4

Diameter of the Bearing Journal that Supports the Differential Housing

Part NumberPart Description Dimension

6%&3026'6%&7#82

differential case 7#.044 0.013 (2.*#4# 0.000#inch)

4+&06**'4+&088#

differential housing 7#.038 0.01# (2.*#43 0.0006inch)

differential case

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8R-6619,9C-5348,109-4717,118-5025,191-3576,218-0766,237-9201,

237-9202

75.051 ± 0.015 mm (2.9548 ± 0.0006inch)

7V-2188,9V-4330

differentia ca!e 75.050 ± 0.015 mm (2.9547 ± 0.0006inch)

8R-2538,9C-8161,103-2010,138-1612,143-9513,206-9670

differentia ca!e 75.040 ± 0.015 mm (2.9543 ± 0.0006inch)

365-1300,365-1301,365-1302

h"#!in$80.00 ± 0.013 mm (3.1496 ± 0.0005 inch)

differentia h"#!in$

5%-1030,8&-8740,8&-9544

fan$e haf "f the differentia ca!e 152.588 ± 0.020 mm (6.0074 ± 0.0008inch)

'ain haf "f the differentia ca!e 152.512 ± 0.020 mm (6.0044 ± 0.0008inch)

8&-9543,8-0244,104-4698,124-6022

fan$e haf "f the differentia ca!e 174.81 ± 0.02 mm (6.8823 ± 0.0008 inch)


203-2289,

282-1775

fan$e haf "f the differentia ca!e 174.70 ± 0.02 mm (6.8779 ± 0.0008 inch)


1V-6983,5V-1272,5V-5630,5V-9322,6&-1565,6&-2968,

fan$e haf "f the differentia ca!e82.625 ± 0.015 mm (3.2530 ± 0.0006inch) 'ain haf "f the differentia ca!e

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7V-7793,8K-6507,8K-7581,8V-2958,9K-5654,9V-5725

3K-4176,1V-5085,8K-5992,9K-5650

flange half of the differential case82.601 ± 0.013 !3.252 ± 0.0005 inch"

#lain half of the differential case

141-3124,279-5128

flange half of the differential case 241.450 ± 0.025 !9.50569 ± 0.001inch"

#lain half of the differential case 489.468 ± 0.025 !19.2704 ± 0.001inch"

271-1674,289-8600,289-8601

flange half of the differential case 88.975 ± 0.015 !3.503 ± 0.0006 inch"


8$-9737,144-4464

differential ho%sing 88.977 ± 0.013 !3.5030 ± 0.0005inch"

co&er for differential ho%sing 85.057 ± 0.013 !3.3487 ± 0.0005inch"

6'-3413,9(-9771,106-6580



2V-3954,9(-8278



1V-5869,3K-9516,4V-4076,

flange half of the differential case

inch"

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7-5013,8-6995 #lain half of the differential case 110.038 ± 0.013 !4.3322 ± 0.0005

inch"

173-5349,171-4736

flange half of the differential case110.038 ± 0.015 !4.3322 ± 0.0006inch" #lain half of the differential case

171-6760,323-4150


171-6763,323-4151,333-4622



333-4623flange half of the differential case

110.038 ± 0.015 !4.3322 ± 0.0006inch" #lain half of the differential case

4V-6451,6K-5626


8$-8503flange half of the differential case


252-7945,256-1109,256-3746,258-2398,265-9508,265-9509

differential case 85.80 ± 0.015 !3.3780 ± 0.0006 inch"

4-6104,8$-7834,8$-8142,104-6746,

159-7446

large diaeter of differential case 96.913 ± 0.015 !3.8155 ± 0.0006inch"

sall diaeter of differential case 85.80 ± 0.015 !3.378 ± 0.0006 inch"

211-0095 differential ho%sing 50.00 ± 0.013 !1.9685 ± 0.0005 inch"

9K-4911 co&er for differential ho%singinch"





9K-1394 co&er for differential ho%sing77.8383 ± 0.013 !3.0645 ± 0.0005inch"

4-3191,

104-6738

half :ith the gear of the differentialcase

88.977 ± 0.013 !3.5030 ± 0.0005inch"


3K-3396flange half of the differential case


8K-7437,9K-5643

co&er for differential ho%sing 82.6008 ± 0.013 !3.252 ± 0.0005inch"

8$-9281,8$-9440,104-3359,136-6550,144-4465,372-4788



85.057 ± 0.013 !3.3487 ± 0.00051inch"

8$-8141,8$-8336,102-7507,102-7519,

108-2836,127-9096,142-0444,148-9288


114.385 ± 0.015 !4.5033 ± 0.0006inch"


6K-7636



2-6286 co&er for differential ho%sing 110.038 ± 0.013 !4.3322 ± 0.0005inch"

5K-6694 co&er for differential ho%sing 104.826 ± 0.013 !4.127 ± 0.0005inch"

9/-0471,105-4026








242-8686,367-2024

139.81 ± 0.015 !5.5043 ± 0.0006inch"

#lain half of the differential case 114.4 ± 0.015 !4.5039 ± 0.0006 inch"

1V-6318



8$-6188



4V-5391,6'-1631,105-2073,129-6659,149-0191



2-6708,8V-9808



8$-4769,100-4504



8K-9585 co&er for differential ho%sing 114.376 ± 0.013 !4.5030 ± 0.0005inch"






2S-0300,7K-9308,8K-7398

114.376 ± 0.013 mm (4.5030 ± 0.0005inch)

plain half of the iffe!ential ca"e 133.426 ± 0.020 mm (5.2530 ± 0.0008inch)

4#-8733

flan$e half of the iffe!ential ca"e 114.351 ± 0.013 mm (4.5020 ± 0.0005inch)


8%-2669,

5#-2756



7#-9623



2&-2630,4%-5630,4%-5730,6%-0736,7%-7660,8'-6756,101-7513,107-7857



2&-9200,6%-8531,6&-7560,6&-7565,8%-5620



3%-9561,6%-8540 flan$e half of the iffe!ential ca"e 139.776 ± 0.020 mm (5.5030 ± 0.0008

inch)

plain half of the iffe!ential ca"e

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Documents

Guia de reusabilidad de diferencial