Professional Documents
Culture Documents
April 2004
SMCS Code: 4050
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
Reusability of Drive Train Gears
Abnormal Wear.....................................................27
Table of Contents
Introduction .............................................................3
Frosting .............................................................27
References .............................................................3
Pitting ................................................................30
Corrosion / Corrosive Pitting .........................33
Destructive Pitting .........................................39
Spalling .............................................................43
Pitting/Spalling ..................................................49
Glossary of Terms...................................................4
Scoring ..............................................................53
Gear Types..........................................................5
Abrasive Wear...................................................65
Nicks .................................................................69
Cracks ...............................................................71
Chipping ............................................................74
Uneven Contact ................................................77
Foreign Object Damage ....................................79
Rippling .............................................................87
Lipping...............................................................88
Rolling/Sliding Action...........................................9
LPSTC/HPSTC..................................................10
Lubrication Thickness........................................11
Splines................................................................100
Cleaning................................................................11
Thrust Faces.......................................................101
Notes ..................................................................103
Table 1
Summary of Revisions
Page
Description
All
Revised Format
All
100
Added Splines
101
Introduction
This Guideline enables dealers and their
customers to benefit from cost reductions made
possible through an established parts
reusability and salvage program. Every effort
has been made to provide the most current and
relevant information known to Caterpillar Inc.
Since the Company makes ongoing changes
and improvements to its products, this
Guideline must be used with the latest technical
information available from Caterpillar to ensure
such changes and improvements are
incorporated where applicable. You may also refer
to Analyzing Gear Failures, Form SEBF8045.
References
Table 2
References
Form No.
SEBF8193-03
Title
SEBF8185
SEBF8187
SEBF8148
NENG2500
SEBF8029
Description
Small Flashlight
170-5903
4C-4735
1U-5566
1U-6444
146-1738
Borescope
8S-2257
154-1296
9U-7377
8T-7765
6V-2010
Polishing Stone
Gear Nomenclature
Glossary of Terms
Profile: A gear tooth profile is known as the
shape or outline of the gear tooth as it is seen
from the side of the gear.
Addendum: The addendum is the section of
tooth that is above the pitch line.
Pitch Line: The pitch line is located between
the HPSTC and the LPSTC where there is no
sliding action between the two mating gear
teeth surfaces.
Crown: A gear tooth crown is the outline that
can be seen from the top of the tooth. You will
be able to notice the slight convex or round
outline (see item 23, Illustration 1). The slightly
rounded shape of the tooth crown compensates
for minor gear tooth misalignment. The crown
can also help distribute the load from the center
of the tooth outward for more efficiency.
Dedendum: The Dedendum is the section of
the gear tooth that is below the pitch line.
HPSTC: Highest Point of Single Tooth Contact.
LPSTC: Lowest Point of Single Tooth Contact.
Illustration 1
This illustration shows the key elements of a gear. The
elements in this illustration are identified in the Chart A
(Gear Tooth Nomenclature).
Table 4
Chart A
Gear Tooth Nomenclature
Item
Description
12
End
13
Tip
14
Tip Land
15
Edge
16
Tooth Face
17
18
Pitch Line
19
20
Fillet
21
Root
22
23
Crown
24
Profile
25
26
Thrust Face
SEBF8193-03
Gear Types
Illustration 3
Helical Gears
Helical gears have parallel or perpendicular shafts.
Helical gears are quiet. Multiple teeth carry the load.
Illustration 2
Spur Gears
Spur gears have parallel shafts. The load is applied to
one single tooth and one third of the adjacent tooth.
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Illustration 4
Illustration 5
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Machine Application,
Operation and Maintenance
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a.
b.
c.
Illustration 7
If you mishandle a gear, the teeth may chip. The gear in
the above illustration had been mishandled.
E71149
Illustration 6
Do not set gears on the floor or stack them on top of each
other.
SEBF8193-03
Metallurgy
Operational Characteristics of
Gears
The information in this section will explain the
different operational characteristics of gears.
The basic gear terminology will also be
explained in this section
Rolling/Sliding Action
Competitive Gears
R-S
R
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PL
R-S
E71044
Illustration 8
The rolling/sliding action that occurs as a gear rotates is
shown in this illustration.
(A) - Loaded side of tooth
(B) - Unloaded side of tooth
(R) - Rolling action
(R-S) - Rolling-sliding action
(PL) - Pitch line
LPSTC/HPSTC
Load/Contact Velocity
Illustration 10
When you operate a gear in the No Wear zone (2) it will
have maximum operating life, but the oil must be clean.
Maximum gear life will occur under medium gear speeds,
and low/medium gear loads.
If the oil is contaminated, the wear line (1) will increase at
a steeper angle, shifting the complete graph toward the
origin.
Illustration 9
LPSTC/HPSTC.
(24) - Driven gear
(25) - Driving gear
(26) - Beginning of tooth contact with rolling and sliding
action (LPSTC)
(27) - Full tooth contact with rolling action
(28) - End of tooth contact with rolling and sliding action
(HPSTC)
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10
Lubrication Thickness
Cleaning
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11
Inspection Procedure
Illustration 11
During the inspection process, use a clean, white, nonglossy piece of paper in order to reflect light onto the face
of each gear tooth.
Illustration 12
Notice the white plastic bench top. It is easy to clean, light
reflective, and will not damage the gears if they are
dropped onto it.
SEBF8193-03
a. Gear rim.
b. Splines (if applicable).
c. Bearing surfaces (if applicable).
4. Bearing bores. Bearing bores may have
minimal wear or damage only.
5. Follow and fill out the Gear Inspection
Checklist (Chart B) in order to ensure that the
gear is inspected for all types of possible
damage.
12
Table 6
Chart C
Tooling and Equipment
Table 5
Item
Chart B
Gear Inspection Checklist
Part Number
Polishing Stone
6V-2010
Black Light
4C-4715
Loupe
8S-2257
Borescope
8T-9290
Microscope (Optional)
6V-2196
Abnormal Wear
4C-4736
Frosting
4C-4735
Pitting
Penetrant
9U-6337
Initial
8T-7765
Corrosive
9U-7377
Destructive
Developer
9U-6338
Spalling
Pitting \ Spalling
Scoring
Seal Pick
Item
Yes
No
Normal Wear
White Layer Flaking
High Hour Wear
Case Crushing
Corrosion/Corrosive Pitting
Abrasive Wear
Nicks
Cracks
Chipping
Uneven Contact
Foreign Object Damage
Rippling/Lipping
Gear Bores
Planet Gear Bores
Gears with Replaceable
Bearing Races
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13
Liquid Non-Fluorescent
Penetrant Method
Tooling for this method requires a 4C-4736 or a
9U-6335 Liquid Penetrant Kit.
Note: This method will not always find shallow
cracks of 0.05 mm (0.002 inch) or
smaller.
SEBF8193-03
14
SOS Testing
Reconditioning
NOTICE
If the tooth has a raised metal area, remove
only the raised portion on the tooth surface.
Do not try to remove pitting or any other
recessed surface damage. Do not use a
grinder or power polisher; use only a handheld stone. Using power tools to remove
damage can also remove the case hardened
surface of the gear, causing eventual failure.
Illustration 13
A stone and oil should be used in order to polish a tooth.
Be aware of the adjacent tooth. The corner of the stone
can easily damage adjacent teeth.
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15
Illustration 14
A grinder had been used on this gear in an attempt to
recondition the teeth. If you need to recondition the teeth
on any gear, use the stone and the oil. Do not use a
grinder. A grinding process can remove the case
hardened surface of a gear.
Illustration 15
The marking code is "1-15". This gear has been through
one rebuild. This gear had 15,000 hours on it when it was
rebuilt.
Illustration 16
SEBF8193-03
The marking codes are "1-12" and "2-10". This gear has
been through two rebuilds. The gear had 12,000 hours on
it when it was rebuilt for the first time. The gear had
22,000 hours on it when it was rebuilt for the second time.
16
Machining
This section covers the basic stages that are required in order to machine a gear.
Illustration 17
The horizontal marks (arrows) were created during the manufacturing process. These marks are rough machining marks.
The marks may look like cracks but are not. Use one of the crack inspection methods in order to make sure that the marks are
not cracks.
Use again
SEBF8193-02
17
Illustration 18
The burrs that are on this gear tooth may look like lipping, but they are not. The machining process can leave burrs on the
edges of gear teeth. Dull cutting tools can cause these burrs.
Use again
SEBF8193-03
18
Rough Machining
Gear teeth are often machined by using a hobbing process. If a gear has been through a hob process,
you will easily notice the rough machining marks on the surfaces of the teeth and the burrs on the
edges of the teeth.
Illustration 19
This gear has been through the rough machining process. A hob tool was used in this process.
Illustration 20
You can visually see the hob machining marks (1) on gear tooth face. The rough machining marks and burrs that are left from
the hobbing process will be removed during the finish machining process.
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19
Finish Machining
After the gear teeth have been cut with the hob process, a finish machining process is used. This
process is called shaving. Illustration 21 shows the typical appearance of a new gear that has just
passed through the shaving process. This gear is ready for heat treatment.
Illustration 21
This is a new gear that has not been through the heat treat process yet. The shaving marks (2) that are shown in this
illustration will be visible after thousands of hours of use. These marks are positioned on the tooth face at a slight angle.
Since the root fillet area is not a contact surface, it does not need to undergo the finish machining process. Therefore, the hob
marks (1) will be left in the root fillet. This gear is ready for heat treatment.
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20
Illustration 22
This is a magnification of the gear that was shown in Illustration 21. You can see the shaver marks (2) more clearly. The hob
marks (1) are also visible in the fillet.
Illustration 23
This gear tooth shows an acceptable, even contact wear pattern after thousands of hours of use. This gear's wear pattern is
an ideal wear pattern. The pattern of wear is centered and even on the tooth. During operation of the gear train, the shaving
marks will slowly wear away. Notice how the contact ends before it gets to the edges or the tip of the gear tooth. The gear
teeth are designed this way in order to reduce the occurrence of chipping at the edges and scoring at the tips.
Use again
SEBF8193-03
21
Illustration 24
These marks (A) may look like cracks but they are actually shaver marks from the shaving process. Inspect this gear for
cracks with any one of the crack inspection methods.
Use again
Illustration 25
Sometimes, a machining mark will look like a crack. If the gear appears to have a crack, inspect it with one of the crack
inspection methods. Because machining marks are not usually deep, they should not show up during a crack detection
process. Normal wear will smooth the surfaces and should be evenly distributed across the teeth.
Use again
SEBF8193-03
22
Normal Wear
This section will describe the types of normal wear patterns that a gear can develop. The two types of
normal gear wear are white layer flaking, and high hour wear. If a gear has only normal wear, it can
generally be used again.
Illustration 26
Normal wear is shown in this example. The machining marks (arrows) on this gear are still visible.
Use again
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23
Illustration 27
Although the flaking of the skin appears to be destructive, it is not and this gear may be reused.
Use again
Illustration 28
This is a magnified view of the thin brittle skin (1) that can develop on nitride-hardened gears.
Use again
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24
Illustration 29
The rough machining marks have caused the load to become concentrated in certain areas. Notice how the pattern of the
white layer flaking follows the machining marks.
Use again
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25
Illustration 30
This gear illustrates normal high hour wear. After you check for other types of abnormal wear, this gear may be reused.
Adjust the alignment during the build so that the wear will be centered on the teeth of this gear.
Use again
Illustration 31
Normal wear is shown in this example. The machining marks (arrows) are still visible on this gear.
Use again
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26
Abnormal Wear
This section describes the different types of abnormal wear.
Frosting
Frosting occurs when mating gear teeth undergo metal-to-metal contact. The metal-to-metal contact
usually results from an inadequate film of oil between the surfaces of mating gear teeth. Frosting is not
harmful to the gear as long as pitting has not started and as long as the profile has not changed.
Frosting appears like a "cloudy gray" area on the gear contact surface. A gear that shows signs of
frosting can be used again as long as it is free from other types of damage.
The following may cause frosting:
a. High Operating temperatures which cause the lubrication viscosity to become thin
b. High loads
c. Incorrect lubrication
d. Incorrect part
e. (Etc.)
Frosting itself is not harmful to the gear. However, if the conditions that cause frosting are not
corrected, pitting can start and lead to destructive pitting and spalling.
E71150
Illustration 32
Frosting appears on the gear contact surface and it usually occurs in an even wear pattern. Frosting is displayed in this
illustration as small surface pits that are along the pitch line. Always check for pitting damage and profile damage before you
reuse a frosted gear.
SEBF8193-03
27
Illustration 33
Correct the cause of frosting in order to avoid pitting. A classic example of frosting appears as a "cloudy gray" area on the
gear contact surface. This condition is caused by inadequate oil film between two mating gear teeth surfaces. There is no
pitting present in this example.
Use again
Illustration 34
This is an example of frosting. Because there is no pitting present, this gear may be reused. Correct the load alignment
during the installation process.
Use again
SEBF8193-03
28
Illustration 35
Pitting (1) and frosting (2) are both shown on the gear that is in this illustration. The frosting (2) is acceptable. However,
because destructive pitting will usually occur with frosting (2), you must reference the Pitting section of this guideline in order
to determine that the pitting (1) is not destructive. After you determine that the pitting (1) is not destructive, the gear may be
reused.
Use again
Illustration 36
Reuse of this gear depends on application, operation, and maintenance.
Borderline
SEBF8193-03
29
Pitting
Pitting is the development of small holes in the surface of a tooth. Pitting is a sliding contact stress
fatigue failure on the surface of a gear tooth. The holes usually occur low on the gear tooth near the
lowest possible single tooth contact (LPSTC).
There are two types of pitting:
a. Initial pitting will usually occur during the machine break-in period (up to 500 hours). Initial pitting is
normal. As long as the application, operation, and maintenance are correct, instances of initial
pitting will rarely progress into destructive pitting. When the break-in period is over, the initial pitting
will usually stop.
b. Destructive pitting will usually occur after the machine break-in period (over 500 hours). Destructive
pitting will usually be found on most or all of the gear teeth. If the causes of destructive pitting are
not corrected, the deep pits will progress into spalling, and then into tooth fracture.
E71168
Illustration 37
Notice the small pits that are located near the LPSTC on this gear tooth.
SEBF8193-03
30
Illustration 38
The initial pitting (1), shown in this illustration should not progress into destructive pitting. Check for other types of abnormal
wear before you reuse this gear.
Use again
Illustration 39
The arrows show an instance of initial pitting. Lightly polish the area with an 8T-7765 Scotch Brite Pad and oil.
Use again
SEBF8193-03
31
Illustration 40
This gear has some initial pitting (arrow) just at the SAP (Start of Active Profile). Check for other types of abnormal wear
before you reuse this gear.
Use again
Illustration 41
This illustration is a magnification of Illustration 40.
Use again
SEBF8193-03
32
Illustration 42
Corrosion has caused corrosive pitting. The pitting covers a good percentage of this gear tooth.
SEBF8193-03
33
Illustration 43
Corrosive pitting, in an advanced stage, will take over the entire face of a gear tooth. This stage of corrosive pitting is usually
followed closely by spalling.
Illustration 44
The corrosive pitting on this gear has developed into a spall.
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34
Illustration 45
Because the corrosive pitting shown here is only located on the ends of the gear teeth, this gear may be used again.
Use again
Illustration 46
This image shows a gear that has undergone corrosion. Corrosion may create shallow surface deposits. These deposits
visually appear as discoloration. Use a microscope in order to examine the deposits. If the gear shows signs of pitting, do not
reuse the gear. The gear shown above has been examined and does not show any signs of pitting.
Use again
SEBF8193-03
35
Illustration 47
Remove the rust that is on this gear. If the source of the problem (usually a source of Water) is not discovered and corrected
immediately, corrosion will cause corrosive pitting.
Illustration 48
The rust pits (1), shown in this illustration, are visible. Because rust has caused pitting on the teeth of this gear, it should not
be used again.
SEBF8193-03
36
Illustration 49
The appearance of the teeth on this gear is the only thing affected by corrosion. The texture of this gear remains smooth and
the gear does not show any signs of pitting. Corrosive pitting has not yet occurred on this gear. Correct the cause of the
corrosion before you reuse this gear.
Use again
Illustration 50
This gear may not be used again because it is heavily rusted. The cause of the rust is usually water mixing with the oil. Check
other gears for rust and replace them if necessary. Before you rebuild the drive train, make sure the source of moisture has
been eliminated.
SEBF8193-03
37
Illustration 51
The corrosion in this illustration has not caused pitting.
Use again
Illustration 52
The corrosion that is shown in this illustration has progressed past the first stage in corrosion. The gear that is in this
illustration may appear to be reusable, however, a good light source and a good magnification will reveal that the gear tooth is
actually discolored and rough.
SEBF8193-03
38
Destructive Pitting
Destructive pitting usually occurs only after a long period of operation (over 500 hours). Destructive
pitting can be found on most or all of the gear teeth. Destructive pitting can start as micro pitting and
progress into a spall. The spalled tooth will eventually fracture.
E71169
Illustration 53
Destructive Pitting is shown in this illustration. The large pits across the LPSTC are destructive pits. This type of pitting can
penetrate the case hardened surface of a gear.
Illustration 54
If the lubrication film is inadequate, micro pitting (1) may occur. Micro pitting is a type of destructive pitting that can be caused
by metal to metal contact. The micro pitting (1) that is shown in this illustration is in its early stages. Therefore, this gear can
be used again. Determine the cause of insufficient lubrication and correct it before you reinstall the gear.
Use again
SEBF8193-03
39
Illustration 55
Notice how the destructive pitting (2) is much deeper than initial pitting (1). The destructive pitting (2) is near the LPSTC and
has penetrated the case hardened surface.
Illustration 56
This is a magnified view of the pitting (1) that is shown in Illustration 55.
SEBF8193-03
40
Illustration 57
Although the pitting shown here is widespread, it has penetrated the case hardened surface.
Illustration 58
Reuse of this gear depends on application, operation, and maintenance.
Borderline
SEBF8193-03
41
Illustration 59
The pitting on this gear is borderline. Check for other types of abnormal wear. Base your decision on the application,
operation, and maintenance of the machine.
Borderline
Illustration 60
Micro pitting (1) and macro pitting (2) are shown in this illustration. Because the macro pitting (2) is developing into a spall,
this gear cannot be reused.
Do not reuse
SEBF8193-03
42
Spalling
Spalling is a type of subsurface fatigue failure. Spalling is a result from a small fatigue crack that has
worked it's way up the face of the gear tooth while remaining under the case hardened surface. Either
destructive pitting or case crushing can cause spalling. A destructive pit is usually the starting point for
a spall. As a spall starts to progress, it will travel from the destructive pit, up the face of the tooth.
Throughout this process, the crack will remain beneath the case hardened surface. When a crack
travels beneath the case hardened surface of a gear tooth, it is traveling the path of least resistance.
As the subsurface crack progresses towards the tip of the tooth, the case hardened surface will break
away in small pieces. These pieces will continue to break away until the spall has reached the tip of
the tooth. A spall will form in the shape of a "V". This process happens over a length of time. Once
the protective case hardened surface has deteriorated, the weak inner core will be left unprotected. A
tooth that has spalling damage will eventually fracture. In order to detect spalling damage in the drive
train, schedule a Caterpillar certified SOS oil analysis. If you do not make the necessary repairs,
spalled teeth can fracture and cause significant damage to the drive train system. Do not reuse any
gear that has spalling damage.
Note: Spalling is often confused with case crushing. It is important to know the differences.
1. Destructive pitting is the leading cause of spalling. Look for instances of destructive pitting. If
destructive pitting is not present, the damage may be due to case crushing.
2. Examine the damaged area. Spalling will not leave pieces of crushed metal. Case crushing will
leave pieces of the case.
3. When a gear tooth has spalling damage, the shape of the damage will be like a "V". Damage
from a crushed case is usually in a rectangular shape.
4. Refer to the Case Crushing section in this guideline for more information.
Spalling damage is shown in the following illustrations.
Before a spall occurs, you will be able to see the outline in the face of the tooth. An outline of spalling
damage will look like a tornado. Do not reuse any gear with a "tornado" shaped outline on the tooth
face.
Once the spall progresses, the case hardened surface will slowly break away.
Examples of spalling damage are shown in the next several photos. Do not reuse any gear with
spalling damage.
SEBF8193-03
43
E71188
Illustration 61
Notice how the spall starts at destructive pitting and climbs up the tooth face in a V shaped pattern. Illustrations 62 thru 66
show the growth of a spall. For orientation purposes, the tooth tip (1) and the tooth fillet (2) will be called out in the following
illustrations.
Illustration 62
Stage 1: The starting point of a spall (arrow) is pointed out below the pitch line.
SEBF8193-03
44
Illustration 63
Stage 2: A small fatigue crack at the surface of the gear is shown here. Metal starts to flake off the tooth face at this point.
Illustration 64
Stage 3: The small subsurface cracks will join and the tooth face will flake away.
SEBF8193-03
45
Illustration 65
Stage 4 shows the small subsurface cracks. These cracks continue to join, as the spalling damage area grows larger.
Illustration 66
Stage 5 shows where the spalling has progressed across the tooth face. Stage 6 will be a tooth fracture.
SEBF8193-03
46
Illustration 67
The arrow shows an area on the gear tooth where spalling is in an early stage. These pits are becoming connected by small
subsurface cracks.
Illustration 68
As the subsurface cracks grow, a piece of the tooth face will flake off.
SEBF8193-03
47
Illustration 69
Most spalls develop in a V shape. Sometimes, the "V" shape is not always distinctive. Even if the shape is not a complete
"V", a spall will grow from narrow too wide as it progresses up the face of the tooth.
Illustration 70
The spalling shown here has originated from pitting damage (arrow).
SEBF8193-03
48
Pitting/Spalling
Pitting/spalling is the transition process between pitting and spalling. A gear with evidence of
pitting/spalling should not be used again. Spalling can progress rapidly into a tooth fracture.
Illustration 71 shows a cross-section view of spalling and it's present state just prior to a tooth fracture.
Illustration 71
This is a cross-section of the progression from pitting to spalling. Notice how the destructive pitting has caused subsurface
cracks in hardened tooth surface.
SEBF8193-03
49
Illustration 72
This cross section shows a spalled gear tooth. Notice how the destructive pitting (arrow) can cause subsurface cracks in the
case hardened surface of the tooth.
Illustration 73
Spalling is a type of subsurface fatigue fracture that removes flakes of metal and can progress rapidly into a tooth fracture.
Notice how the subsurface cracking can cause a tornado outline on the face of the gear tooth. This area will eventually
fracture and look similar to the damage that is shown in the next illustration.
Do not reuse
SEBF8193-03
50
Illustration 74
Notice how this spall progresses up the tooth face from the destructive pitting at the bottom of the tooth. This spall is in the
common V shape.
Illustration 75
Destructive pitting (1) is shown along the LPSTC and destructive pitting (2) is shown near the pitch line. Subsurface cracking
exists just beneath the destructive pitting (2). The destructive pitting (2) is in the process of progressing into a spall. The spall
on the front tooth will look like the spall on the back tooth. The spall (3) is shown progressing from the destructive pitting to the
HPSTC in a V shaped pattern up the tooth.
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51
Illustration 76
This illustration shows a cross section view of a spall fatigue thats in its early stages. A spall thats in this stage is difficult to
detect because it starts in the core material of the gear. Once the cracks reach the case hardened surface, a spall fatigue can
rapidly progress into a tooth fracture.
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52
Scoring
Scoring, also known as adhesive wear, can result from metal-to-metal tooth contact and can cause
vertical scratches, which are perpendicular to the pitch line. Scoring begins above and/or below the
pitch line where sliding action occurs between two mating teeth. Scoring damage should not occur at
pitch line because only rolling action is present at this location.
Scoring can occur when the oil film is not adequate, during periods of excessive load, and
misalignment. Severe scoring will produce an irregular furrowed surface on the tooth face.
Reuse a gear with scoring damage only if the tooth face is relatively smooth and only if the scoring has
not altered the shape of the tooth profile. Before you reuse a gear with scoring damage, refer to the
crack detection section in order to check for cracks.
E71195
Illustration 77
Scoring is usually located above or below the pitch line. Scoring is the result of metal-to-metal tooth contact.
SEBF8193-03
53
Illustration 78
The scoring (1) that is shown in this illustration is in an early stage. Because of this, the gear may be used again.
Use again
Illustration 79
This is a magnification of Illustration 78. The scoring has not penetrated the case hardened surface.
SEBF8193-03
54
Illustration 80
In this illustration, the scored areas (vertical scratches) are above and below the pitch line (PL). At the pitch line, there is only
rolling action. Because of this, scoring will not occur at the pitch line (PL).
Illustration 81
The shaver marks (arrows) in this illustration were made during the final machining operation in the manufacturing process.
Shaver marks can be confused with scoring marks. Scoring marks are vertical. Shaving marks will be positioned at a slight
angle and will cover the entire width of the tooth face. The shaving marks that are shown in the above illustration are not
harmful (refer to the "Machining" section at the front of this Guideline for additional information).
Use again
SEBF8193-03
55
Illustration 82
The arrows in this illustration show scoring marks that are excessive enough to make this gear unusable. Notice that damage
is below the pitch line.
Illustration 83
Check the profile of each gear tooth. If the profile has changed do not use this gear again.
Borderline
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56
Illustration 84
If scoring damage above the pitch line is smooth and the profile has not changed, this gear may be reused.
Use again
Illustration 85
This illustration is a magnified view of Illustration 84.
SEBF8193-03
57
Illustration 86
The scoring (vertical scratches) is above the pitch line. Because the tooth face is smooth, the gear may be used again.
Use again
Illustration 87
The lipping damage (1) has changed the tooth profile. A gear with lipping damage should not be used again.
SEBF8193-03
58
Illustration 88
Severe scoring has damaged the profile of the teeth on this gear.
Illustration 89
The tooth profile (1) is damaged and irregular. Notice how the scoring has changed the tooth profile (1).
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59
Illustration 90
Scoring has damaged the tooth profile. A corrected load alignment will help to prevent the same type of damage to the
replacement gear. Locate and correct the cause of load misalignment.
Illustration 91
This gear has medium sized abrasive wear. Stone and lightly polish the rough edges before you reuse this gear. Because the
abrasive wear is towards the tip of the teeth, the gear may be reused. Always check the profile in order to ensure that it is free
from damage.
Use again
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Case Crushing
Case crushing is a failure of the case hardened surface of a gear. The case (surface) of a tooth is
much harder than the core (center) of a tooth. Case crushing has an appearance much like something
that has shattered. When a case crushing failure occurs, the softer core material becomes exposed.
Because the softer core material is unable to withstand the normal loads placed on the gear, a gear
tooth with a crushed case will quickly fracture. Gears with evidence of case crushing cannot be used
again.
E71201
Illustration 92
The case hardened wear surface has failed and the core is exposed. Gears with this type of wear should not be reused
because the soft core is unable to withstand the normal loads placed on the teeth.
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E71234
Illustration 93
This illustration shows a cross section of a gear. The components consist of a hardened case (1) and a softer inner core (2).
Illustration 94
This gear has been saw cut, polished, and acid etched. In this cross-section, you can see the case hardened surface. Every
Caterpillar gear goes through a proprietary heat treat process.
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Illustration 95
A misaligned load or a shock load can cause case crushing. Case crushing may also occur if the case hardened surface is
thin. A gear with evidence of case crushing should not be reused.
Do not reuse
Illustration 96
Case crushing (arrow) is shown in the illustration above. The cracks in the tooth face are hard to see in this early stage. You
must use one of the crack inspection methods in order to detect the damage.
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Illustration 97
As a gear progresses through the stages of case crushing, horizontal cracks across the tooth face will become visible. The
"shattered" appearance is unique to case crushing.
Illustration 98
In the final stage of case crushing, material from the tooth face will flake off. The edges to the cavity are sharp and
perpendicular to each other. Distinguishing the difference between case crushing damage and spalling damage can be
difficult. The cavity that results from a crushed case is usually larger and deeper than the cavity that results from a spall.
Experience is the best guide when you need to distinguish the difference between the two types of damage.
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Abrasive Wear
Abrasive wear is caused by small contaminants such as soil, sand, or metal in the lubrication system.
The small particles will eventually wear down the surface of the teeth and can even alter the gear
profile. Abrasive material can travel throughout the drive train gear system and damage other gears as
well. Therefore, if you find that one gear has abrasive wear, check the other gears in the drive train
system as well.
Light abrasive material will cause the gear to appear gray matte in color. The smallest contaminants
will lightly polish a gear's teeth. If light abrasive wear is not corrected, the teeth will become shiny
enough to resemble a mirror. Medium to large sized contaminants will usually produce scratches, cuts,
and bruises on the gear teeth. Large particles can create deep grooves on the tooth face.
If you find evidence of abrasive wear, correct the source of the contamination immediately. A gear with
limited abrasive wear may be reused as long as the profile has not changed and as long as the gear
does not have any other types of damage.
E71138
E71138
Illustration 99
This illustration shows a diagram of advanced abrasive wear around the pitch line area. Advanced abrasive wear will alter the
tooth profile.
(1) Heavy wear
(2) Pitch line
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Illustration 100
The gear that is shown in this illustration is in an early stage of the abrasive wear process. The teeth on this gear have a
satiny appearance with no flat spots on the profile. The gear can be used again after you correct the source of the
contamination.
Use again
Illustration 101
The teeth on this gear appear to have a "satiny" finish. On this gear, the abrasive wear has advanced from the early stages of
abrasive wear displayed in the previous illustration. Notice the machining marks and polishing marks on the right side of the
teeth. The machining marks are still visible toward the tips of the gear teeth.
Use again
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Illustration 102
This is the next stage in the abrasive wear process. When abrasive wear is allowed to continue, the gear teeth will develop a
mirror-like finish. The finish will be so shiny; each tooth will reflect an image of the adjacent tooth.
Illustration 103
Notice the areas above and below the pitch line. The scratching on the surface of these teeth hints that large foreign particles
were present in the lubrication system. The normal sliding action is responsible for this massive amount of wear above the
pitch line. Bruising has also occurred on the teeth of the gear.
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Illustration 104
This gear has been exposed to a significant amount of abrasive wear. The arrow in this illustration indicates a heavy wear
groove. A significant amount of abrasive wear is capable of causing a depression like this.
Illustration 105
The case hardened surface has been worn away and has exposed the softer core. This damage will quickly progress into a
tooth fracture.
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Nicks
Nicks usually occur when a gear is mishandled before heat treatment. Because most nicks will occur
before heat treatment, a gear with a nick can be reused.
Illustration 106
This gear has a nick on the tip of the tooth.
Use again
Illustration 107
This nick (1) occurred before heat treatment. Before you reuse this gear, verify that the damage is not a crack.
Use again
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Illustration 108
This tooth has been nicked on the tooth face and in the fillet. Before you reuse this gear, verify that the damage is not a crack.
Use again
Illustration 109
The nick that is shown on this gear is on the tooth tip land (arrow). Nicks on any tooth tip land or edge are acceptable as long
as they do not extend onto the tooth contact surface. Use a stone and oil in order to polish the rough edges around the nick.
Use again
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Cracks
It is difficult to visually distinguish a difference between a scratch and a crack. To determine if cracks
are present, a crack inspection method must be used in order to inspect the gear. See the "Crack
Inspection Methods" section of this guideline for more information about the necessary equipment and
procedures that are needed in order to determine if cracks are present.
Illustration 110
These cracks are located in the fillet area of the tooth. A dye penetrant crack inspection method has been used in order to
detect the cracks that are shown in this illustration.
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Illustration 111
This gear has a crack (arrow) towards the end of the tooth. The liquid florescent dye penetrant crack inspection method has
been used in order to find the crack that is shown in this illustration.
Illustration 112
Cracks have developed in the root areas of this gear. It was necessary to use the dry magnetic particle inspection method in
order to locate these cracks.
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Illustration 113
The crack in the root area of the tooth has progressed toward the gear bore from the tooth the fillet. Sometimes it is very
difficult to see a crack like this unless you use one of the crack detection methods.
Illustration 114
This crack has developed in the root area in between two teeth and the crack has progressed all the way through the gear.
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Chipping
Illustration 115
The chip (arrow) on this gear is from mishandling. Unlike a nick, a chip will always occur after heat treatment.
Use again
Illustration 116
This is a magnification of Illustration 115
Use again
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Illustration 117
The ends of the teeth are chipped because foreign objects have damaged them. Polish the sharp edges with a stone and oil.
Inspect the gear for cracks using a crack inspection method.
Use again
Illustration 118
The tooth end has been chipped because the gear had been mishandled. Since this chip extends into the fillet area (A), you
should not reuse this gear. The tooth may break off during operation and cause significant damage to other components in
the drive train system.
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Illustration 119
The chipping damage extends onto the contact surface of the gear tooth.
Illustration 120
This chip (1) does not extend onto the contact surface. Polish the rough edges that are around the chip (1) with a stone and
oil.
Use again
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Uneven Contact
E71182
Illustration 121
The five most common types of uneven wear patterns are shown in this illustration.
(1) Normal contact pattern. Maximum gear life (Application, operation, and maintenance procedures must be adequate.)
(2) Tooth end contact pattern. Tooth breakage can occur.
(3) Tooth tip contact. Scoring, pitting, and tooth breakage can occur.
(4) Concentrated root contact. Scoring and pitting can occur.
(5) Concentrated tip contact. Scoring, pitting, and tooth breakage can occur.
Illustration 122
In this illustration the contact pattern (1) is highly concentrated toward the end of the tooth. The contact pattern is a "Type 2"
uneven contact pattern. Because the contact pattern (1) is not centered on the tooth, this gear should not be used again.
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Illustration 123
The contact pattern (arrow) is a "Type 2" uneven contact pattern. This is a typical example of a severe wear step. The
contact pattern is not centered on the tooth.
Illustration 124
The arrows in this illustration point out severe wear steps. This type of wear is also caused by a "Type 2" uneven contact
pattern.
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Illustration 125
The foreign object damage to this ring gear has not penetrated the case hardened surface. The root fillet area is not
damaged.
Use again
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Illustration 126
The foreign object damage (1) is large and deep. The damage is also near the fillet.
Illustration 127
The foreign object damage on this gear is just above the pitch line.
Use again
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Illustration 128
The foreign object damage (arrows) is at the pitch line.
Use again
Illustration 129
The foreign object damage (arrows) is at the pitch line and below the pitch line. The foreign object damage that is below the
pitch line does not extend into the root fillet.
Use again
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Illustration 130
The foreign object damage (1), near the pitch line, is acceptable. However, because the foreign object damage (2) extends
into the fillet area of the tooth, this gear cannot be reused.
Illustration 131
This illustration is a magnification of Illustration 130. The fillet has foreign object damage (2).
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Illustration 132
The foreign object damage (arrow) has penetrated the case hardened surface.
Illustration 133
The foreign object damage on this tooth exists in the fillet (arrow). Examine the tip of the meshing gear tooth for similar
damage.
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Illustration 134
The tip of the mating gear tooth (arrow) is embedded into the fillet. Do not reuse this gear or the mating gear with the broken
tooth. Inspect other gears in the drive train for damage.
Illustration 135
The face of this tooth is severely cracked. Foreign object damage can cause a tooth to crack.
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Illustration 136
The face of this tooth is severely cracked, which is the result of foreign object damage. The wide gap that is between each
stress line and the deep ridges indicates that this crack happened quickly.
Illustration 137
The tips of these teeth are severely cracked, which is the result of foreign object damage.
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Illustration 138
The deep indentation that is shown on the gear above is from a roller bearing.
Illustration 139
This type of foreign object damage was caused by soft debris. Usually, soft debris will not cause a significant amount of
damage.
Use again
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Rippling
Illustration 140
This gear has rippling damage (shown between the lines). This type of damage would be most common on highly loaded gear
teeth.
Illustration 141
Rippling has advanced from scoring, to pitting, and then to a change in profile.
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Lipping
Illustration 142
Lipping is the permanent displacement of surface metal. Lipping will happen if a gear is too soft or if a gear is overloaded
during adequate lubrication. If the lubrication were not adequate, the damage would be a combination of scoring, metal
pullout, and smearing.
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Gear Bores
Drive train gear bores are very sensitive to damage. If the gear is to be reused, the bore must not have
any wear or damage. Like all other inspection processes, a good light source is required in order to
fully inspect the bore of a gear.
Refer to the cleaning section of this guideline in order to clean the bore of the gear. If gear bore has
stains that cannot be removed with 8T-7765 Scotch Brite Pad and solvent, do not reuse the gear. A
gear with minimal bore damage can be reused. Because gear bores are very sensitive to damage, it is
important that you make a careful reuse decision for any gear bore. If a gear bore has two or more
different types of damage, it should not be reused. Gears with lightly damaged gear bores may be
reused as long as each of the following conditions are true:
Illustration 143
This bore is in excellent condition and there is no visible damage.
Use again
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Illustration 144
If a gear bore is used as a race for a bearing, it should not be worn or damaged. There is no wear or damage in this gear
bore.
Use again
Illustration 145
Foreign objects have damaged the bore of this planet gear.
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Illustration 146
Use a stone and oil in order to remove the sharp edges around the nick (1) before reusing this gear.
Use again
Illustration 147
If a bore has stains like these, you should clean the bore of the gear. Refer to the Cleaning section of this guideline for more
information. If you clean the gear bore and you still find instances of pitting, do not reuse the gear.
The standard cleaning procedures were applied to the bore of the gear in this illustration. The discolored lines were still there.
The discolored lines inside this gear bore are instances of pitting.
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Illustration 148
Like the bore in the previous illustration, the stains could not be removed from the bore of this gear. The stains are instances
of pitting.
Illustration 149
This gear bore has been damaged in both the area of the bearing roller track (1) and the area of the retaining washers (2).
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Illustration 150
Use good lighting when you inspecting any gear bore. If the surface of the bore has an irregular contour, the beams of light
will not be straight.
Illustration 151
The bearing retaining washers have spun inside the gear bore.
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Illustration 152
Brinelling will create a washboard appearance and texture on the surface of the bearing bore. Do not reuse a gear with a bore
that has brinelling damage.
Illustration 153
This gear bore has corroded. Notice how the corrosion makes a pattern of parallel bands in the bore.
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Illustration 154
The bore on this planet gear has spalled (arrows).
Illustration 155
The gear bore that is shown in the above illustration has corroded.
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Illustration 156
Examine both edges of the gear bore. This nick is along the edge of the gear bore and is the only instance of damage to the
bore. Therefore, the gear may be reused. The nick has not penetrated the case hardened surface. Polish any protruding
edges that are around the nick with a stone and oil.
Use again
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Illustration 157
The bearing race has crept inside this bore and has caused only a small amount of damage. If the bore is still within
specification, it may be used again. The dark brown or black appearance may be caused from gear oil and can be removed
with an 8T-7765 Scotch Brite Pad and solvent. If the bore is not within tolerance, follow the Reuse and Salvage procedure
that is outlined in SEBF8185 Salvage Procedure for Final Drive Planet Gears Used in Off-Highway Trucks, before you install
the new bearing.
Use again
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Illustration 158
The bearing race that was in this gear has spun inside the gear bore. If a gear bore is blue in color, do not reuse it. The blue
temper color in the bore was caused by extreme temperatures (overheating). If a gear bore becomes overheated, it cannot be
used again.
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Illustration 159
The bore of this gear has spun around a shaft. The bore is beyond the limit for reuse. The teeth are also heavily damaged.
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Splines
Spline wear can be determined by the use of a seal pick. With a seal pick held perpendicular to the
spline tooth, check for wear steps in the spline teeth that stop the seal pick. If the pick is stopped by
any of the wear steps, do not reuse the gear. Visually check for other types damage on the spline
before you reuse it.
Illustration 160
Use a seal pick (1) in order to determine if a spline can or cannot be reused. Hold the pick in a position that is perpendicular to
the spline tooth that you are checking. Drag the seal pick across the wear step (3). If the pick is stopped by the wear step, do
not reuse the spline. The fillet radius (2) is also shown above.
Illustration 161
This gear has spline wear that does not stop a seal pick. Check the wear at the ends of the spline engagement as well. As
long as there is no other damage, this spline may be used again.
Use again
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Thrust Faces
The thrust face on a planet gear, sun gear, or side gear should not have smears or heat checks. Heat
checks are shallow cracks that interrupt the lube film and can shave off material from the thrust bearing.
Gears with light thrust face damage can be used again. Light scratches are acceptable only when they
do not stop a seal pick. If you notice a sharp edge on the thrust face, remove it with a stone and oil.
Illustration 162
This planet gear thrust face is in good condition. The gear may be used again as long as there are no cracks in the surface of
the thrust face. Use one of the crack inspection methods that are described in the "Crack Inspection Methods" section of this
guideline.
Use again
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Illustration 163
This differential side gear is approaching the wear limit, however, because this gear does not have any other damage, it may
be used again. The roughness and damage (arrows) are at the maximum allowable limit for reuse.
Use again
Illustration 164
The roughness and damage (arrow) level of the complete thrust surface does not meet the standards for reuse. Also note the
discoloration.
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Notes
SEBF8193-03
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