Reusabilidad de Engranajes

771D Truck 6JR00001-00134 (MACHINE) POWERED BY 3408E Engine(SEBP247...
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Cerrar SIS
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Producto: QUARRY TRUCK
Modelo: 771D QUARRY TRUCK 6JR
Configuracin: 771D Truck 6JR00001-00134 (MACHINE) POWERED BY 3408E Engine
Pautas de reutilizacin y recuperacin

Reusability of Drive Train Gears{3002, 3159, 3256, 4055}
Nmero de medio -SEBF8193-13
Fecha de publicacin -07/11/2011
Fecha de actualizacin -07/11/2011
i04539678
Reusability of Drive Train Gears{3002, 3159, 3256, 4055}

SMCS - 3002; 3159; 3256; 4055
Articulated Truck: All
Backhoe Loader: All
Challenger: All
Cold Planer: All
Compact Track Loader: All
Compact Wheel Loader: ALL
Earthmoving Compactor: All
Excavator: All
Integrated Toolcarrier: All
Landfill Compactor: All
Load Haul Dump: All
Motor Grader: All
Off-Highway Truck/Tractor: All
Paving Compactor: All
Pipelayer: All
Telehandler: All
Track-Type Loader: All
Track-Type Skidder: All
Track-Type Tractor: All
Underground Articulated Truck: All
Wheel Dozer: All
Wheel Loader: All
Wheel Tractor-Scraper: All
Introduction
Table 1
Revision
Summary of Changes in SEBF8193
13
Updated Crack Detection Procedure, Reviewed Part Numbers
11 and 12
Update Group Effectivity
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 01/03/2012
771D Truck 6JR00001-00134 (MACHINE) POWERED BY 3408E Engine(SEBP247...Page 2 of 156
10
Added Asphalt Paver to Group Effectivity
2011 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 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.
Summary
This Guideline contains information which can help to determine visually the reusability of gears
in the drive train. This Guideline also contains the operational characteristics of gears in the drive
train. The information that is shown in this guideline will help to explain the cause and succession
of a failure. Never install a part that is shown in this Guideline as a part that cannot be used again.
This Guideline can help to identify the gears that may be used again by illustrating the typical
modes of failure. This Guideline cannot guarantee that any individual gear can be reused. There is
always some risk of failure. Experience and careful inspection is the best guideline for proper
usage of gears.
Important Safety Information

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 in order to
perform these functions properly. Safety precautions and warnings are provided in this instruction
and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to
you or to other persons. Caterpillar cannot anticipate every possible circumstance that might
involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on
the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that
is not recommended by Caterpillar is used, you must 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.
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on
this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as
danger, warning, or caution. The "WARNING" safety alert symbol is shown below.
Illustration 1
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. You must determine that the tools, procedures, work methods, and
operating techniques are safe. You must determine that the operation, lubrication,
maintenance, and repair procedures will not damage the machine. Also, you must 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.
References
Use the following references for additional information regarding the rebuild of a drive train.
Table 2
References
SEBF8185
Reuse And Salvage Guidelines "Salvage Procedure for Final Drive Planet Gear
Used in Off-Highway Trucks"
SEBF8187
Reuse And Salvage Guidelines "Standardized Parts Marking Procedures"
SEBF8148
Reuse And Salvage Guidelines "General Salvage and Reconditioning

Techniques"
SEBF8029
Reuse And Salvage Guidelines "Index of Repair Process Engineering

Publications"
Tooling and Equipment

Table 3
Part Number
Item
170-5903
Gear Inspection Stand Gp
6V-2010
Polishing Stone
1U-5566
280-8961
Ultraviolet Lamp Gp
Lamp Kit
8S-2257
Eye Loupe
146-1738
8T-9290
Borescope Inspection Group
262-8390
Microscope
263-7184
Crack Detection Kit
4C-4804
Dye Penetrant
8T-7765
Surface Reconditioning Pad
9U-7377
Metal Marking Pen
4C-4805
Developer
288-4209
Paper Towel
5P-1720
Seal Pick
Reflective Surface for Inspection
Bright Incandescent Light
Nomenclature of Gears
Illustration 2
g01876519
Key elements of a gear are identified in Table 4.
Table 4
Nomenclature of Gear Teeth

Item
Description
End
Tip
Land of tip
Edge
Face of tooth
Highest point of single tooth contact (HPSTC)
Pitch Line
Lowest point of single tooth contact (LPSTC)
Fillet
10
Root
11
Start of active profile
12
Crown
13
Profile
14
Pitch diameter of gear
15
Thrust face
Glossary of Terms
Profile - The profile of the gear teeth is the shape or the outline of the gear tooth from the side of
the gear.
Addendum - The addendum is the section of tooth that is above the pitch line.
Pitch Line - The pitch line is located between the highest point of single tooth contact (HPSTC)
and the lowest point of single tooth contact (LPSTC). Sliding between the surfaces of gear teeth
does not occur at the pitch line.
Crown - The crown of a gear tooth is the outline that can be seen from the top of the tooth. The
crown is shown as item (12) in Illustration 2. The roundness of the crown of a tooth compensates
for a minor misalignment between the teeth of a gear. The crown can also help distribute the load
from the center of the tooth outward for more efficiency.
Dedendum - The Dedendum is the section of the gear tooth that is below the pitch line.
Gear Types
Illustration 3
g01397610
Spur Gears
Spur gears have parallel shafts. The load is applied to one single tooth. The load is applied to approximately 1/3 of
the adjacent tooth.
Illustration 4
g01397614
Helical Gears
Helical gears have either parallel shafts or perpendicular shafts. Helical gears are quiet. Multiple teeth carry the load.
Illustration 5
g01397616
Straight Bevel Gears

Straight bevel gears have either angled shafts or perpendicular shafts. Approximately 1 and 1/3 teeth carry the load.
Some end thrust is produced.
771D Truck 6JR00001-00134 (MACHINE) POWERED BY 3408E Engine(SEBP2... Page 10 of 156
Illustration 6
g01397623
Spiral Gear
Hypoid pinions or spiral gear shafts are perpendicular to each other. The gear teeth are curved in order to provide
more contact area between mating teeth. The design creates quiet operation with more sliding tooth contact, and end
thrust. Two or more teeth carry the load.
Case Hardened Surface

All Caterpillar gears are heat-treated. Caterpillar Gears are designed by persons that select the
proper material and heat treatment which enables Caterpillar gears to meet desired standards for
performance, life, and durability. Most Caterpillar gears are case hardened in order to provide the
gears with a hard, durable surface, and a strong, tough core.
There are several different case hardening heat treatments. The most typical treatments for
Caterpillar gears are nitriding and carburizing. Nitriding provides a shallower hardened case
typically from 0.13 mm (0.005 inch) to 0.3 mm (0.01 inch). Nitrided gears, which require higher
dimensional accuracy, are loaded with lighter loads. Carburized gears are typically utilized in
applications with the highest loads. The carburized gears are typically used in final drives. The
depths of the case can vary from 0.5 mm (0.02 inch) to 2.0 mm (0.08 inch).
The proper selection of design, materials, and heat treatment produce gears that are capable of
providing the best life and performance in the harshest applications.
Machine Application, Operation, and Maintenance

Consider the following information in all decisions to reuse gears:
Machine application
Machine operation
Machine maintenance
Assume high hours, insufficient maintenance, and heavy applications if the history of the
machine is not known. Decisions for reusing gears should never be based on one characteristic.
Gears are designed to withstand the sliding action between the surfaces of mating teeth. Gears are
not designed to withstand conditions of insufficient lubrication. Insufficient lubrication can cause
direct contact between gears. Direct contact increases resistance and operating temperatures.
Inadequate lubrication will cause serious damage if regular maintenance is ignored. These
conditions will eventually contribute to abnormal wear or accelerated wear during operation.
Methods for Minimizing Gear Failures

1. Gear trains are easily contaminated during field assembly. Use clean procedures at all times.
Clean procedures will always minimize the possibility for contamination.
2. Use only the recommended procedures for assembly. Proper levels of oil should be
maintained. Only use Caterpillar recommended lubricants in order to minimize internally
generated debris from wear.
3. Replace any breathers that are dirty in order to minimize airborne contamination.
4. Schedule a Scheduled Oil Service (SOS) that is certified by Caterpillar in order to find
possible causes of oil contamination. An oil analysis can help determine the cause of a
failure. An oil analysis can also assist in the prevention of possible future failures. Keep an
accurate record of the machine hours and application. The information will be used during
the oil analysis in order to generate the most accurate diagnosis.
5. The specified filters should be used and changed at the recommended intervals if gear oil
passes through a system of filters.
6. Change the drive train oils at the recommended intervals. The intervals can be found in the
Service Manual for the machine.
7. Be certain that all gears are free of rust and debris during a rebuild. Examine the gears in
order to check for any damage from handling.
Illustration 7
g01397978
Do not place gears on the floor or stack the gears on top of each other.
8. Gears should be handled carefully. Gears should be stored properly during rebuilding. Gears
are easily chipped. A chipped tooth is shown in Illustration 8.
a. Do not stack the gears or place the gears on the floor. Illustration 7 shows the
improper way of stacking gears.
b. Stack the gears in a stable pattern. Place the large gears on the bottom and the smaller
gears toward the top. Use cardboard to separate the gears when gears are stacked.
c. Use a nylon sling in order to lift a gear. Use of a nylon sling will help to prevent
damage to the bore of the gear. Follow all Caterpillar safety standards for operating a
hoist.
9. Record the history of the machine. Record the hours of usage for the component.
Illustration 8
g01397997
Not properly handling a gear may cause the teeth to break. The gear in the above illustration was not handled
properly.
10. Record the number of rebuilds and hours on all gears. Refer to ""The Procedure for Marking
Codes" " for more information.
Operational Characteristics of Gears

The information in this section will explain the basic terminology and different operational
characteristics of gears.
Caterpillar Genuine Gears

Caterpillar gears deliver maximum performance and productivity under extreme loads. The teeth
of the gears move against each other. The teeth are under high stress in order to convert engine
horsepower into torque. Caterpillar gears in drive trains are built with the purpose of transmitting
extreme loads. The gears are built to work as a system with the following unique features:
Smooth tooth surfaces
Resistance to pitting and scoring
Prevention of excess contact and stress on meshing teeth
Geometry of teeth that is resistant to breaking
Metallurgy of gears that is specific to applications
Proprietary heat-treat processes

The properties of Caterpillar gears differentiate the gears from other replacement or
remanufactured gears. Maximum machine performance and productivity can be ensured by
installing genuine Caterpillar gears in your Caterpillar equipment. Caterpillar gear teeth are
specially shaped in order to distribute stress over a large area. The shape of the gears prevents
tooth fracture.
Competitive Gears
Competitive manufacturers of gears claim to produce gears that can be used in many different
machines because the gears are designed for multiple pieces of equipment. Every Caterpillar gear
has a specific design for each application. These acute yet important differences are critical to the
life of any drive train. The use of Caterpillar gears will ensure correct gear tooth contact and
efficient power flow under varying load conditions. Only Caterpillar genuine gears should be
installed into Caterpillar equipment.
Metallurgy
Caterpillar gears have unique metallurgical compositions. The metallurgical content of each gear
is tailored to the specific application of the gear. Caterpillar improves the impact resistance of the
gears. Caterpillar also ensures the proper transfer of loads and consistency by utilizing special
steel formulas.
Case Hardened Surface

Highly loaded gears in the drive train require a case hardened surface. All gears in the drive train
are heat treated to a specified level of hardness. The depth of the case hardened surface depends
on the size of the gear, the application of the gear, and the metallurgy of the gear. The Caterpillar
patented heat treat process can offer extended gear life to highly loaded gears in drive trains. The
smallest Caterpillar gears will usually be heat treated to a depth of at least 0.20 mm (0.008 inch).
Large Caterpillar gears can be heat treated to a depth of 12.70 mm (0.500 inch).
Rolling Action and Sliding Action

The gear teeth go through a combined rolling and sliding action when gears rotate in and out of a
mesh. Rolling and sliding occurs during contact above the pitch line and below the pitch line.
Only rolling occurs at the pitch line.
Illustration 9
g01876614
The illustration shows the rolling and sliding action that occurs as a gear rotates.
(14) Pitch diameter
(16) Loaded side of tooth
(17) Unloaded side of tooth
(18) Rolling action
(19) Rolling and sliding action
LPSTC and HPSTC

The LPSTC is low on the gear tooth. Pitting usually occurs at the LPSTC. The HPSTC is high on
the gear tooth. Scoring usually occurs at the HPSTC and above the HPSTC.
Illustration 10
g01876993
LPSTC and HPSTC

(6) HPSTC
(8) LPSTC
(20) Driven gear
(21) Driving gear
(22) Full tooth contact with rolling action
Load and Velocity of Contact

The load on gear teeth and the velocity of gear tooth contact relate to each other. Wear increases
with increases in load. Scoring increases with increases in the velocity of contact.
Illustration 11
g01877013
Gears have maximum operating life in zone (24). The oil must be clean. Maximum life of the gear will occur under
medium gear speeds. Maximum life of a gear will occur under lower loads on gears. The line of wear (23) will
increase at a steeper angle if the oil is contaminated. Oil contamination will shift the complete graph toward the
origin.
(23) Wear
(24) No wear with clean oil
(25) Scoring
(26) Pitting
(27) Breakage
(28) Velocity of contact
(29) Load
Thickness of Lubrication
The thickness of the lubrication film is important. The temperature of the lubrication, the amount
of the lubrication, and speed of the gear can affect the thickness of the lubrication. The thickness
of lubrication can also affect the type of wear. Refer to Illustration 11 for the following
combinations of the usage of gears.
Slow gear speed - A slow gear speed can allow the oil to leave the surface of the gear. Slow gear
speeds can cause metal contact. At a slow gear speed, the gear teeth will have insufficient
lubrication.
Fast gear speed - A fast gear speed can cause the teeth to penetrate the thin film of lubrication
during operation. Gear speeds that are too fast usually result in metal tooth contact.
High loads on gears - A high load at a slow velocity of gear contact will have accelerated wear
characteristics. High loads can penetrate a thin film of lubrication. A high load can break the film
of lubrication at both slow gear speeds and fast gear speeds. Accelerated wear can happen at slow
speeds. Breakage and pitting may happen at high gear speeds.
High velocity of gear contact - High velocities of gear contact will usually cause scoring. High
velocities of contact with elevated loads will usually cause pitting .
Cleaning
Gears require cleaning prior to inspection.
1. Remove the gears from the machine or the component. Clean the gears in a solvent with a
petroleum base. The dark brown or black appearance in the bore of a gear may be caused
from gear oil. The dark brown or black appearance can be removed with an 8T-7765
Surface Reconditioning Pad and solvent. Lightly polish the darkened area with a 8T-7765
Surface Reconditioning Pad .
2. Every gear tooth should be clean. Remove the excess solvent with a clean, dry paper towel
in order to remove any deposits or oil.
3. Apply a thin layer of oil on the gears if the gears will be stored after inspection. Store the
gears in a clean, dry place.
Inspection Procedure
Accurate inspection is an important necessity for the life of any gear. The maximum life of any
drive train can be obtained through proper inspection and repair procedures. Refer to ""Tooling
and Equipment" " for a list of tooling for inspection. When you examine a gear, always use good
lighting. If an unacceptable gear is reused, it's possible that the gear will fail. The gear that failed
will destroy other components in the drive train. The technician that is performing the inspection
should be familiar with all types of gear wear and damage. The most common reasons for gear
failure are described in this Guideline. Decisions on reusing gears are helped by close inspections.
Illustration 12
g01398402
Use a clean, white piece of paper with a dull finish in order to reflect light onto the face of each gear tooth during the
inspection process.
Use the following tools in order to identify damaged areas during the inspection process:
Magnifying glass
Strong light source
White paper
Illustration 12 shows the inspection process.
Clean, white paper without a shiny finish can reflect the light onto dark surfaces. A magnifying
glass or magnifying glass with a lamp may also be helpful during the inspection process. Refer to
Reuse And Salvage Guidelines, SEBF8148, "General Salvage and Reconditioning Techniques"
for detailed information on inspection.
Process for Inspecting Gears

1. Clean all gears thoroughly before inspecting the gears. Refer to ""Cleaning" ".
2. Inspect the entire surface area of the gear for the following damage:
Pitting
Spalling
Cracking
Any other damage
It is possible for only one tooth to be damaged.
3. Carefully inspect the bore of the gear with a bright light. Bearing bores for planetary gears
can be sensitive to high loads and speeds. Careful inspection for damage is critical.
a. Rim of gear
b. Spline
c. Bearing surface
Illustration 13
g01398419
Notice the white plastic on top of the bench. It is easy to clean the surface. The surface reflects light. Also,
the surface will not damage the gears on contact.
4. Bearing bores may have minimal wear or damage only.

5. Use Table 5 in order to ensure that the gear is inspected for all possible damage.
Table 5
Checklist for Inspecting Gears
Item
Yes
No
Normal wear
White layer flaking
Wear from high hour
Abnormal wear
Frosting
Pitting
Initial
Corrosive
Destructive
Spalling
Pitting or spalling
Scoring
Case crushing
Corrosion or corrosive pitting
Abrasive wear
Nicks
Cracks
Chipping
Uneven contact
Damage from foreign object
Rippling or lipping
Bores in gears
Bores in planetary gears
Gears with replaceable bearing races
Table 6
Part Number
Item
6V-2010
Polishing Stone
1U-5566
Ultraviolet Lamp Gp
8S-2257
Eye Loupe
146-1738
8T-9290
Borescope Inspection Group
262-8390
Microscope
263-7184
Crack Detection Kit
4C-4804
Penetrating Oil
8T-7765
Surface Reconditioning Pad
9U-7377
Metal Marking Pen
4C-4805
Developer
288-4209
Paper Towel
5P-1720
Seal Pick
Reflective Surface for Inspection
Bright Incandescent Light
Crack Detection
Crack Detection Systems
Crack detection systems commonly used are dye and florescent liquid penetrant, dry powder and
liquid magnetic particle methods, and ultrasonic testing. There may be more than one acceptable
crack detection system for the inspection of a given part, although the florescent penetrant is most
versatile. Select the method that best fits your shops operation. Sometimes, characteristics of a
particular part may prevent the use of certain inspection systems. For example, a liquid penetrant
system cannot be used to inspect for subsurface cracks in a steel part. Use Table 7 to determine the
best system for the type of structure being inspected.
Table 7
Inspection System vs. Material Structure
Type Of Structure
Inspection Method
Weld Joint
Nonferrous
Ferrous
Dye Penetrant
Fluorescent Penetrant
Dry Magnetic Particle
(1)
Liquid Magnetic Particle
(1)
Ultrasonic Testing
(1)
Magnetic particle inspection of any steel or cast iron weld joint will always show a crack indication.
Advantages and Disadvantages

Table 8
Advantages vs. Disadvantages
Detection System
Dye Penetrant
Fluorescent Penetrant
Advantages
Disadvantages
Least expensive.
Minimal training
required.
Portable
Works on nonmagnetic
parts.
Least sensitive.
Detects only surface cracks.
More expensive.
More sensitive.
Works on nonmagnetic
parts.
Requires power for light.

Detects only surface cracks.
Dry Magnetic Particle Portable

Fast.
Works only on magnetic parts.

Not as sensitive as fluorescent materials.
Liquid Magnetic
Particle
More sensitive than dry

powder.
Detects subsurface as
much as
0.13 mm (0.005 inch).
Requires power for light.

Works only on magnetic parts.
Liquid composition and agitation must be
monitored.
Ultrasonic Testing
Most sensitive.
Detects deep material
defects.
Most expensive.
Requires operator training and
certification.
Tooling Available
Liquid Penetrant
Dye: 4C-4736 Dye (Includes cleaner, dye, and developer)
Fluorescent: 4C-4714 Black Light, 4C-4715 Clamping Fixture for Black Light, 4C-4737 Cleaner/
Remover Fluid, 4C-4738 Penetrant, 4C-4739 Developer
Magnetic Particle
Dry powder: 4C-4735 Accessory Kit (Includes magnetic yoke, powder, cleaner)
Note: Liquid Magnetic Particle: Not offered by Caterpillar Inc. Use commercially available
material.
Note: Caterpillar Inc does not offer ultrasonic testing equipment. A specially trained operator is
required to use and interpret the ultrasound equipment and data.
Inspection Procedures
Personal injury can result from improper handling of chemicals.

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.
Observe all safety precautions recommended by the chemical
manufacturer for handling, storage, and disposal of chemicals.
To inspect for cracks using the dye penetrant, use the following procedures prepared by the
Magnaflux Corporation:
Illustration 14
g02052134
1. Preclean inspection area. Spray on cleaner / remover. Wipe off with cloth.
Illustration 15
g02052134
2. Apply penetrant. Allow short penetration period.
Illustration 16
g02052139
3. Spray cleaner / remover on wiping towel and clean surface clean.
Illustration 17
g02052153
4. Spray on a thin, uniform film of developer.
Illustration 18
g02052140
5. Inspect. Defects will show as bright red lines in while developer background.
To inspect for cracks using the fluorescent penetrant, use the following procedures prepared
by the Magnaflux Corporation:
Illustration 19
g02052197
1. Preclean inspection area. Spray on cleaner / remover. Wipe off with cloth.
Illustration 20
g02052199
2. Apply penetrant. Allow short penetration period.
Illustration 21
g02052200
3. Spray cleaner / remover on wiping towel and wipe surface clean.
Illustration 22
g02052201
4. Apply a thin film developer. Allow a short developing period. For rough surfaces, daub on a
dry developer.
Illustration 23
g02052202
5. Inspect under black light. Cracks and lack of bond will show as glowing lines, porosity as
spots.
To inspect for cracks using the magnetic particle system, use the following procedures
prepared by the Magnaflux Corporation:
Illustration 24
g02053634
1. Preclean inspection area. Spray on cleaner. Wipe off with cloth.
Illustration 25
g02053635
2. Place yoke on test piece perpendicular to direction of suspended cracks.
Illustration 26
g02053636
3. Energize yoke. Magnetic field will form in test place.
Illustration 27
g02053637
4. Apply magnetic powder or prepared bath while yoke is energized.
Illustration 28
g02053638
5. Indications will appear immediately.
Scheduled Oil Sample Testing

An oil analysis that is certified by Caterpillar should be scheduled. The oil analysis should be
based on the machine application and the schedule of hours. Change your oil on a regular basis.
Refer to the operating manual in order to acquire the recommended oil change intervals, oil
capacity, and the type of oil. Regular oil changes and Scheduled Oil Samples are the best ways to
discover oil contamination. Regular oil changes and Scheduled Oil Samples also prevent oil
contamination. An SOS oil analysis may also help determine the cause of a failure.
Reconditioning
Gears with limited damage on the surface may be used again after the damaged area has been
polished with 6V-2010 Polishing Stone and oil. Caterpillar recommends the use of a polishing
stone and oil. Never use a die grinder in order to recondition a gear. A die grinder can remove the
case hardened surface of a gear. Refer to Illustration 30.
NOTICE
If the tooth has a raised metal area, remove only the raised portion on
the tooth surface. Do not try to remove pitting or any other recessed
surface damage. Do not use a grinder or power polisher, use only a
hand-held stone. Using power tools to remove damage can also remove
the case hardened surface of the gear, causing eventual failure.
Illustration 29
g01398432
6V-2010 Polishing 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.
Illustration 30
g01398463
A grinder had been used on this gear in an attempt to recondition the teeth. Use 6V-2010 Polishing Stone and oil for
reconditioning the teeth on a gear. Do not use a grinder. The grinding process can remove the case hardened surface
of a gear.
DO NOT USE THIS PART AGAIN.
Procedure for Marking Codes

The code is a Caterpillar standard. The code is used in order to record the history of a gear. The
code will identify the number of rebuilds and hours at the time of each rebuild. This information is
important for any decision to reuse a gear. The information should be considered for making the
decision to reuse a gear. The information should be considered for locating the cause of a failure.
The mark should be located on the sides of planetary gears and sun gears. The mark should not be
covered by a mating part. Use 9U-7377 Metal Marking Pen that is listed in ""Tooling and
Equipment" " in order to mark the code onto the gear.
The procedure for marking gears is a Caterpillar standard. This code is helpful when the machine
is sold into a different territory after the first rebuild. During an overhaul, the previous code of a
part should never be removed. For additional information about the procedure, refer to Reuse And
Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures".
Example 1
Illustration 31 shows code (1-15). The first number (1) indicates that the component had been
rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the
time of rebuild.
Illustration 31
g01398471
This gear has been through one rebuild. The gear operated for 15,000 hours when the gear was rebuilt.
Example 2
Illustration 32 shows code (1-12) and code (2-10). Code (2-10) represents the information from
the second rebuild. The first number (2) indicates that the component had been rebuilt twice. The
second number (10) indicates that there were 10,000 hours on the gear at the time of rebuild.
Illustration 32
g01398478
This gear has been through two rebuilds. The gear operated for 12,000 hours when the gear was rebuilt for the first
time. The gear operated for 22,000 hours when the gear was rebuilt for the second time.
Machining
This section covers the basic stages that are required in order to machine a gear.
Illustration 33
The horizontal marks were created during the manufacturing process. These marks are rough machining marks. The marks are not
really cracks. Use one of the inspection methods in order to make sure that the marks are not cracks.
USE THIS PART AGAIN.
Illustration 34
The burrs that are on the gear are not lipping. The machining process can leave burrs on the edges of gear teeth. Dull cutting tools
can cause burrs.
Rough Machining
The gear teeth are often machined by using a hob process. If a gear has been through a hob
process, it is easy to notice the rough machining marks on the surfaces of the teeth and the burrs
on the edges of the teeth.
Illustration 35
This gear has been through the rough machining process. A hob tool was used in this process.
Illustration 36
The marks from the hob (1) are visible on the face of the tooth on the gear in the image. The rough machining marks and burrs that
are left from the hob process will be removed during the final machining process.
Finish Machining
A machining process is used after the gear teeth have been cut with the hob process. This process
is called shaving. Illustration 37 shows the appearance of a new gear that has passed through the
process of shaving. This gear is ready for heat treatment.
Illustration 37
The image shows a new gear that has not been through the heat treat process. The marks from shaving (2) that are shown in
Illustration 37 will be visible after many of hours of use. These marks are positioned on the face of the tooth at a slight angle.
The area of the root fillet is not a contact surface so the area of the root fillet does not need the final machining process. The marks
from the hob (1) will be left in the root fillet. This gear is ready for heat treatment.
Illustration 38
The marks from shaving (2) and the marks from the hob (1) are more visible in the magnification of Illustration 37.
Illustration 39
The wear pattern of the gear that is shown in the illustration is an ideal wear pattern. The pattern of wear is centered and even on
the tooth. During operation of the gear train, the marks from shaving will slowly wear away. Notice that the contact ends before
reaching the tip of the gear tooth. The gear teeth are designed in order to reduce the occurrence of chipping at the edges and
scoring at the tips.
Illustration 40
The image shows marks from the hob (1). Inspect the gear for cracks with any of the methods for inspecting cracks.
Illustration 41
A machining mark may look like a crack. Inspect the gear with any of the methods for inspecting cracks if the gear appears to have
a crack. Machining marks should not appear while detecting cracks. The machining marks are not commonly deep. Normal wear
will smooth the surfaces and normal wear should be evenly distributed across the teeth.
Normal Wear
This section will describe the types of normal wear patterns that can develop by a gear. Normal
gears consist of white layer flaking, and wear from high hours. Usually, gears that only have
normal wear can be used again.
Illustration 42
Normal wear is shown in this illustration. The machining marks are shown by the arrows. The machining marks are still visible on
this gear.
White Layer Flaking

Gears that are hardened by nitride develop a thin brittle skin (2) that may flake off during normal
operation. White layer flaking is a normal type of gear wear. Most gears that show signs of white
layer flaking can be used again.
Illustration 43
White layer flaking (1) is shown. The flaking of the skin appears to be destructive, but the flaking is not destructive. The gear
be reused.
Illustration 44
The image is a magnified view of the thin brittle skin (2) that can develop on gears that are hardened by nitride.
Illustration 45
The rough machining marks have caused the load to become concentrated in certain areas. The pattern of the white layer flaking
follows the machining marks.
Wear from High Hours

The surfaces of gears begin to wear and the surfaces become smooth when loads are applied to
gears. This smooth surface should occur over approximately two-thirds or more of the length of
the gear tooth. Refer to Illustration 46 and Illustration 47.
Illustration 46
g01398788
The gear illustrates normal wear from high hours. This gear may be reused after checking for other types of
abnormal wear. The alignment should be adjusted so that the wear will be centered on the teeth of this gear.
Illustration 47
Normal wear is shown in this illustration. The machining marks are shown by the arrows. The machining marks are still visible on
this gear.
Abnormal Wear
This section describes the different types of abnormal wear.
Frosting
Frosting occurs when gear teeth that are mating undergo metal-to-metal contact. The metal contact
usually results from an inadequate film of oil between the surfaces of mating gear teeth. Frosting
is not harmful to a gear if pitting has not started. Frosting is not harmful to a gear if the profile has
not changed. Frosting appears as a cloudy gray area on the surface of gear contact. Gears that
appear to have signs of frosting can be used again if the gear is free from other types of damage.
Frosting may be a result of the following problems:
High operating temperatures that cause the viscosity of lubrication to become thin
High loads
Incorrect lubrication
Incorrect part
Other similar problems may result in frosting. Frosting is not harmful to the gear. If the conditions
that cause the frosting are not corrected, pitting could result. Pitting can lead to destructive pitting
and spalling.
Illustration 48
g01882514
Frosting appears on the surface of gear contact and frosting usually occurs in an even wear pattern. Frosting is
displayed in the illustration as small pits on the surface that are along the pitch line. Always check for pitting damage
and damage to the profile of the gear before reusing a gear that has frosting.
Illustration 49
Correct the cause of frosting in order to avoid pitting. An example of frosting appears as a cloudy gray area on the surface of gear
contact. The condition is caused by an inadequate film of oil between two surfaces of gear teeth that are mating. There is no pitting
in this example.
Illustration 50
g01398817
This is an example of frosting. This gear may be reused because there is no pitting. Correct the alignment of the load
during the installation process.
Illustration 51
Pitting (1) is shown on the gear. Frosting (2) is also shown. Frosting (2) is acceptable. Destructive pitting will usually occur with
frosting (2). Refer to ""Pitting" " in order to determine that pitting (1) is not destructive. The gear may be reused after determining
that pitting (1) is not destructive.
Illustration 52
Reusing the gear depends on the application, operation, and maintenance.
THRESHOLD
Pitting
Pitting is the development of small holes in the surface of a tooth. Pitting is caused by stress that is
caused by fatigue from contact on the surface of a gear tooth. The holes mainly develop on the
lower part of a gear tooth near the LPSTC of the drive gear. There are two types of pitting.
Initial Pitting - Initial pitting will usually occur during the period of break-in that is up to 500
hours. Instances of initial pitting will seldom progress into destructive pitting if the application,
operation, and maintenance are correct. Initial pitting will usually stop once the period of break-in
is complete.
Destructive Pitting - Destructive pitting will usually occur after the period of break-in up to 500
hours. Destructive pitting will usually be found on most of the gear teeth. The deep pits will
progress into spalling and a fracture if the causes of destructive pitting are not corrected.
Illustration 53
g01882515
Notice the small pits that are located near the lowest point of single tooth contact on this gear tooth.
Illustration 54
Initial pitting (3) should not progress into destructive pitting. Check for other types of abnormal wear before reusing this
Illustration 55
The arrows show an instance of initial pitting. Lightly polish the area with a 8T-7765 Surface Reconditioning Pad and oil.
Illustration 56
This arrow points to initial pitting just at the start of active profile on the gear. Check for other types of abnormal wear before
reuse this gear.
Illustration 57
This Illustration is a magnification of Illustration 56.
Destructive Pitting
Destructive pitting usually occurs after 500 hours of operation. Destructive pitting can be found on
most of the gear teeth. The micro-pitting can lead to destructive pitting and progress into spalling.
The tooth with spalling will eventually fracture.
Illustration 58
g01882516
Destructive pitting is shown in this illustration. The large pits across the Lowest Point of Single Tooth Contact are
destructive pits. Destructive pitting can penetrate the case hardened surface of a gear.
Illustration 59
g01882416
Micro-pitting (4) may occur if the film of lubrication is inadequate. The micro-pitting is a type of destructive pitting
that can be caused by metal contact. The micro-pitting is at an early stage. This gear can be used again. Determine
the cause of insufficient lubrication. Correct the cause of insufficient lubrication before reinstalling the gear.
Illustration 60
Notice that destructive pitting (6) is much deeper than initial pitting (5). Destructive pitting is near the LPSTC. The destructive
pitting has penetrated the case hardened surface.
Illustration 61
g01399944
The image is a magnified view of initial pitting (5) in Illustration 60.
Illustration 62
The pitting is extensive. The pitting has penetrated the case hardened surface.
Illustration 63
Reusing the gear depends on the application, operation, and maintenance.
THRESHOLD
Illustration 64
g01399948
The pitting on this gear is at the threshold. Check for other types of abnormal wear. Base the decision on the
application, operation, and maintenance of the machine. Inspect the dent to determine there are no sharp edges
present.
THRESHOLD
Illustration 65
Micro-pitting (7) and Macro-pitting (8) are shown in the illustration. This gear cannot be reused because the macro pitting is
developing into spalling.
Spalling
Spalling is a type of failure from fatigue that occurs under the surface. Spalling is a result of a
small crack that has passed through the face of the gear tooth and under the case hardened surface.
Either destructive pitting or case crushing can cause spalling. Destructive pitting is usually the
starting point for spalling. Spalling travels from the destructive pit up the face of the tooth.
Throughout this process, the crack will remain beneath the case hardened surface. When a crack
travels beneath the case hardened surface of a gear tooth, the crack travels along the path of least
resistance. As the crack under the surface progresses toward the tip of the tooth, the case hardened
surface will break into small pieces. These pieces will continue to break until the spalling has
reached the tip of the tooth. Spalling will form in the shape of a V. This process happens over a
length of time. Once the protective case hardened surface has deteriorated, the weak inner core
will be left unprotected. A tooth that has spalling damage will eventually fracture. Schedule an
SOS in order to detect spalling damage in the drive train. If necessary repairs are not made, teeth
with spalling can fracture. Teeth that fracture can cause significant damage to the drive train. Do
not reuse any gear that has spalling damage.
Note: Spalling is often confused with the case crushing. It is important to know the differences.
1. Destructive pitting is the main cause of spalling. Look for instances of destructive pitting.
The damage may be due to the case crushing if destructive pitting is not present.
2. Examine the damaged area. Spalling will not leave pieces of crushed metal. Case crushing
will leave pieces of the case.
3. When a gear tooth has spalling damage, the shape of the damage will be in a triangular
shape. Damage from a crushed case is usually in a rectangular shape.
4. Refer to ""Case Crushing" " in this guideline for more information.
Before spalling occurs, the outline in the face of the tooth will be visible. The outline of spalling
damage will be a triangular shape and the tip of the triangle will point downward. Do not reuse
any gear with an outline on the face of the tooth in the shape of a triangle.
Once the spalling progresses, the case hardened surface will slowly break. Examples of spalling
damage are shown in the next photos. Do not reuse any gear with spalling damage.
Illustration 66
g01882554
Notice that the spalling starts at the destructive pitting. The spalling climbs toward the tooth. The spalling is in a
triangular shape. Illustrations 67 through 71 show the growth of spalling. The tip of the tooth (9) and fillet of the
tooth (10) will be called out in the following illustrations.
Illustration 67
Stage 1
The starting point of spalling is visible. The starting point is shown below the pitch line.
Illustration 68
Stage 2
Stage 2 shows a small crack from fatigue at the surface of the gear. Metal starts to flake off the face of the tooth.
Illustration 69
Stage 3
The small cracks under the surface will join and the face of the tooth will flake.
Illustration 70
Stage 4
The small cracks under the surface are shown. The cracks join as the area of spalling becomes larger.
Illustration 71
Stage 5
The spalling has progressed across the face of the tooth. Stage 6 will be a fracture.
Illustration 72
The arrow shows an area on the gear tooth that contains spalling in an early stage. Pits are becoming connected by small cracks
that are under the surface.
Illustration 73
Pieces of the face of the tooth will flake off as the cracks that are under the surface grow.
Illustration 74
Most spalling develops in a triangular shape. The triangular shape is not always characteristic. Even if the shape is not triangular,
spalling will grow as the spalling progresses up the face of the tooth.
Illustration 75
The spalling has originated from pitting damage.
Pitting and Spalling

A combination of pitting and spalling occurs during the process of transition between pitting and
spalling. The wear is due to the sliding and rolling action between the teeth. A gear with evidence
of pitting and spalling should not be used again. Spalling can progress rapidly into a fracture.
Illustration 76 is a cross section of the spalling prior to a fracture.
Illustration 76
This is a cross section of the succession from pitting to spalling. Notice that the destructive pitting has caused cracks that are
the surface in the hardened tooth surface.
Illustration 77
The image shows a cross section of a tooth with spalling. Notice that the destructive pitting can cause cracks under the surface in
the case hardened surface of the tooth.
Illustration 78
g01400142
Spalling is a type of fracture under the surface from fatigue. Spalling causes metal to flake. Spalling can progress
rapidly into a fracture. Notice that the cracking under the surface can cause a triangular shaped outline on the face of
the tooth. The area will fracture and the area will appear similar to the damage that is shown in Illustration 78.
Illustration 79
Notice that the spalling progresses up the face of the tooth from the destructive pitting at the bottom of the tooth. The spalling is
a triangular shape.
Illustration 80
Destructive pitting (11) is shown along the lowest point of single tooth contact and destructive pitting (12) is shown near the pitch
line. Cracking under the surface exists just beneath the destructive pitting. The destructive pitting is in the process of progressing
into spalling. The spalling on the front of the tooth will appear similar to the spalling on the back of the tooth. Spalling (13) is
shown progressing from the destructive pitting to the highest point of single tooth contact. The spalling is triangular in shape.
Illustration 81
The Illustration shows a cross section of fatigue from spalling that is early stage. Detecting fatigue from spalling in an early stage
is difficult. The spalling starts in the core of the gear. Fatigue from spalling can rapidly progress into a fracture once the cracks
reach the case hardened surface.
Corrosion and Corrosive Pitting

Corrosion may be caused by an electrolyte that has entered the lubrication system. The most
common electrolyte is water. Corrosion can lead to corrosive pitting. Correct the cause of
corrosion before corrosive pitting occurs. If an electrolyte enters the drive train, the electrolyte can
neutralize the additive package in the oil.
Early stages of corrosion are not harmful. Most corroded gears can be used again if pitting has not
occurred. During the rebuild, repair the point of entry for the electrolyte.
Rust is a common type of corrosion. Check for corrosive pitting after you remove the corrosion.
Illustration 82
Corrosion has caused corrosive pitting. The pitting covers a good percentage of this gear tooth.
Illustration 83
Corrosive pitting will take over the entire face of a gear tooth in an advanced stage. This stage of corrosive pitting is followed by
spalling.
Illustration 84
The corrosive pitting has developed into spalling.
Illustration 85
The gear may be used again because the corrosive pitting is only located on the ends of the gear teeth.
Illustration 86
g01399416
This image shows a gear that has undergone corrosion. Corrosion may create shallow surface deposits. Shallow
surface deposits visually appear as discoloration. Use a microscope in order to examine the deposits. Do not reuse
the gear if the gear shows signs of pitting. The gear has been examined. The gear does not show any signs of pitting.
Illustration 87
g01399448
Remove the rust that is on this gear. Corrosion will cause corrosive pitting if the source of the problem is not
corrected immediately. The source of corrosion is usually water.
Illustration 88
g01880715
Pits from rust (14) are visible in the illustration. The gear should not be used again because rust has caused pitting on
the teeth of this gear.
Illustration 89
Corrosion only affects the appearance of the gear tooth. The texture remains smooth. There are no signs of pitting. Corrosive
pitting has not yet occurred. Correct the cause of the corrosion before reusing this gear.
Illustration 90
g01399918
This gear may not be used again because the gear is heavily rusted. The cause of the rust is usually water that mixes
with the oil. Check the gears for rust and replace the gears if replacement is necessary. Make sure that the source of
moisture has been eliminated before rebuilding the drive train.
Illustration 91
The corrosion in this illustration has not caused pitting.
Illustration 92
g01399928
The corrosion that is shown in the illustration has progressed past the first stage of corrosion. The gear may appear to
be reusable, but this gear should not be reused. Good lighting and magnification will reveal that the gear tooth is
discolored and rough.
Scoring
Scoring can result from metal to metal tooth contact. Scoring can cause vertical scratches that are
perpendicular to the pitch line. Scoring begins above the pitch line and below the pitch line.
Scoring develops when sliding action occurs between two mating teeth. Scoring damage should
not occur at pitch line because only rolling action is present at this location. Scoring can occur
with inadequate oil, periods of excessive load, speed, and misalignment. Severe scoring will
produce an irregular surface with wrinkles and depressions on the tooth face. Reuse a gear with
scoring damage only if the face of the tooth is relatively smooth and only if the scoring has not
altered the shape of the tooth profile. Inspect the gear for cracks with any of the methods for
inspecting cracks.
Illustration 93
g01882559
Scoring usually occurs above the pitch line or below the pitch line. Scoring is the result of metal to metal tooth
contact.
Illustration 94
Scoring (15) is shown at an early stage in this illustration. The gear may be used again because the scoring is in an early
Illustration 95
This is a magnification of Illustration 94. The scoring has not penetrated the case hardened surface.
Illustration 96
The scoring is located above pitch line (16) and the scoring is located below pitch line (16). There is only rolling action at the pitch
line. Scoring will not occur at the pitch line because of rolling action.
Illustration 97
The marks from shaving in the illustration were made during the final operation of machining. The marks from shaving are shown
by the arrows. Marks from shaving can be confused with scoring marks. Marks from scoring are vertical. Shaving marks will be
positioned at a slight angle. Shaving marks will cover the entire width of the face of the tooth. The marks from shaving that are
shown in the illustration are not harmful. Refer to ""Machining" " for additional information.
Illustration 98
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 99
Check the profile of each gear tooth. Do not use this gear again if the profile has changed.
THRESHOLD
Illustration 100
This gear may be reused if scoring damage above the pitch line is smooth and the profile has not changed.
Illustration 101
This illustration is a magnified view of Illustration 100.
Illustration 102
The scoring is above the pitch line. The scoring appears to be vertical scratches. The gear may be used again because the face of
the tooth is smooth.
Illustration 103
Lipping damage (17) has changed the profile of the tooth. A gear with lipping damage should not be used again.
Illustration 104
Severe scoring has damaged the profile of the teeth on this gear.
Illustration 105
Tooth profile (18) is damaged and irregular. Notice that the scoring has changed the profile of the tooth.
Illustration 106
Scoring has damaged the tooth profile. A corrected alignment of the load will help to prevent the same type of damage to the
replacement gear. Locate the cause of the misalignment of the load and correct the cause of the misalignment of the load.
Illustration 107
This gear has medium sized abrasive wear. Use a 6V-2010 Polishing Stone to polish lightly the rough edges before reusing the
gear. The gear may be reused because the abrasive wear is toward the tip of the teeth. Always check the profile in order to ensure
that the profile is free from damage.
Case Crushing
Case crushing is a failure of the case hardened surface of a gear. The case is the surface and the
core is the center. The case of a tooth is much harder than the core of a tooth. Case crushing
appears similar to an object that has been pulverized. When case crushing occurs, the softer core
may become exposed. The core of a gear is unable to withstand the normal loads. Gear teeth with
crushed cases will quickly fracture. Gears with evidence of case crushing cannot be used again.
Illustration 108
g01882562
The case hardened wear surface has failed and the core is exposed. Gears with a crushed case should not be reused
because the soft core is unable to withstand the normal loads.
The following problems can cause case crushing:

Misalignment
Overload
Shock load
Excessively thin case
Excessively soft core
Gears with evidence of case crushing should not be reused. Gears should be checked for cracks if
shock loading is suspected, or a failure has occurred. Inspect gears for cracks with any of the
methods for inspecting cracks.
Illustration 109
g01882564
This illustration shows a cross section of a gear. The components consist of hardened case (19) and softer inner core
(20) .
Illustration 110
The gear has been cut by a saw. The gear has been polished. The gear has been etched with acid. In this cross section, the case
hardened surface is visible. Every Caterpillar gear goes through a proprietary heat treat process.
Illustration 111
Evidence of case crushing is shown.
Illustration 112
Case crushing is shown in the illustration above. The cracks in the face of the tooth are in an early stage, and the cracks are barely
visible. Inspect the gear for cracks with any of the methods for inspecting cracks.
Illustration 113
Horizontal cracks across the face of the tooth will become visible as a gear progresses through the stages of case crushing. The
pulverized appearance is unique to case crushing.
Illustration 114
In the final stage of case crushing, material from the face of the tooth will flake off. The edges to the cavity are sharp and
perpendicular to each other. Distinguishing the difference between damage from case crushing and spalling damage can be
difficult. The cavity that results from a crushed case is larger than the cavity that results from spalling. Experience is the best guide
when you need to distinguish the difference between the two types of damage.
Abrasive Wear
Abrasive wear is caused by small contaminants in the lubrication system such as the following:
Soil
Sand
Metal
The small particles will eventually wear down the surface of the teeth. The small particles can
even alter the profile of a gear. Abrasive material can travel throughout the gears in the drive train
and abrasive material can damage other gears as well. Check all of the gears in the drive train if
one of the gears has abrasive wear. Light abrasive material will cause the gear to appear dull in
color. The smallest contaminants will lightly polish the teeth of a gear. If light abrasive wear is not
corrected, the teeth will become shiny enough to resemble a mirror. Larger sized contaminants
will usually produce scratches, cuts, and bruises on the gear teeth. Large particles can create deep
grooves on the face of the tooth. If evidence of abrasive wear is found, correct the source of the
contamination immediately. Gears with limited abrasive wear may be reused if the profile has not
changed and the gear does not have any other types of damage.
Illustration 115
g01882565
This illustration shows a diagram of advanced abrasive wear (22) around the area of the pitch line (21). Advanced
abrasive wear will alter the tooth profile.
Illustration 116
The gear that is shown in this illustration is in an early stage of the process of abrasive wear. The teeth on this gear have a shiny
appearance with no flat spots on the profile. The gear can be used again after you correct the source of the contamination.
Illustration 117
The teeth on this gear appear to have a shiny finish. The abrasive wear has advanced from the early stages of abrasive wear. The
early stage of abrasive wear was 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.
771D Truck 6JR00001-00134 (MACHINE) POWERED BY 3408E Engine(SEB... Page 100 of 156
Illustration 118
This is the next stage in the process of abrasive wear. When abrasive wear is allowed to continue, the gear teeth will develop a
finish that resembles a mirror. Each tooth will reflect an image of the adjacent tooth.
Illustration 119
Notice the areas above the pitch line and below the pitch line. The scratching on the surface of these teeth show that large foreign
particles were present in the lubrication system. The normal sliding action is responsible for this large amount of wear above the
pitch line. Bruising has also occurred on the teeth of the gear.
Illustration 120
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.
Illustration 121
The case hardened surface has been worn away and the surface has exposed the softer core. This damage will quickly progress into
a fracture.
Nicks
Nicks usually occur when a gear is not handled properly before heat treatment. Because most
nicks will occur before heat treatment, a gear with a nick can be reused.
Illustration 122
This gear has a nick on the tip of the tooth.
Illustration 123
Nick (23) occurred before heat treatment. Before reusing this gear, verify that the damage is not a crack.
Illustration 124
This tooth has been nicked on the face and in the fillet. Before reusing this gear, verify that the damage is not a crack.
Illustration 125
g01400533
The nick that is shown on this gear is on the tip. Nicks on a tip or nicks on an edge are acceptable if the nicks do not
extend onto the surface of tooth contact. Use a 6V-2010 Polishing Stone and oil in order to polish the rough edges
around the nick.
Cracks
It is difficult to distinguish visually a difference between a scratch and a crack. Inspect the gear for
cracks with any of the methods for inspecting cracks. Refer to ""Inspection Methods" " for more
information about the necessary equipment and procedures that are needed in order to determine if
cracks are present.
Illustration 126
The cracks are located in the fillet of the tooth. 4C-4804 Penetrant has been used in order to detect the cracks that are shown in
illustration.
Illustration 127
This gear has a crack toward the end of the tooth. The liquid fluorescent method has been used in order to find the crack that is
shown in this illustration.
Illustration 128
Cracks have developed in the roots of this gear. It was necessary to use the method for the dry magnetic particle in order to
these cracks.
Illustration 129
The crack in the root of the tooth has progressed toward the bore of the gear. Finding a crack can be difficult and one of the
methods for detecting cracks must be used.
Illustration 130
The crack has developed in the root between two teeth. The crack has progressed all the way through the gear.
Chipping
The wear pattern should be checked on gears with chipping. Misalignment will cause loading off
the end of the tooth. The misalignment can cause chipping. Multiple teeth typically become
chipped under a misaligned load.
Illustration 131
The chip on this gear is from not handling the gear properly. Unlike a nick, a chip will occur after heat treatment.
Illustration 132
The image is a magnified view of Illustration 132.
Illustration 133
The ends of the teeth are chipped because foreign objects have damaged the teeth. Polish the sharp edges with a 6V-2010
Polishing Stone and oil. Inspect the gear for cracks by using any of the methods for inspecting cracks.
Illustration 134
g01882567
The end of the tooth has been chipped because the gear has not been handled properly. Since this chip extends into
fillet (24), the gear should not be reused. The tooth may break during operation and the broken tooth may cause
significant damage to other components in the drive train.
Illustration 135
The damage from shipping extends onto the contact surface of the gear tooth.
Illustration 136
g01882568
Chip (25) does not extend onto the contact surface. Polish the rough edges that are around chip (25) with a stone and
oil.
Uneven Contact
Illustration 137
g01889855
The five most common types of uneven wear patterns are shown in this illustration.
Normal contact pattern (30) will lead to a maximum life if the application, the operation, and the maintenance
procedures are adequate. Contact on the end of the tooth (31) can lead to breakage. Contact at the tip of the tooth
(32) can lead to scoring, pitting, and breakage. The contact that is concentrated at the root (33) can lead to scoring
and pitting. The contact that is concentrated at the tip (34) can lead to scoring, pitting, and breakage.
(30) Normal contact pattern
(31) Contact on the end of the tooth
(32) Contact at the tip of the tooth
(33) Contact that is concentrated at the root
(34) Contact that is concentrated at the tip
Illustration 138
Contact on the end of the tooth is shown.
Contact pattern (31) is shown in the illustration. The contact is highly concentrated toward the end of the tooth. Because the
contact pattern is not centered on the tooth, this gear should not be used again.
Illustration 139
This is a typical example of a severe wear step. The contact pattern is not centered on the tooth.
Illustration 140
The arrows in this illustration point out severe wear steps. This type of wear is also caused by an uneven contact pattern.
Damage from Foreign Objects

Foreign objects are objects that are not permitted in the drive train. A foreign object will
commonly come from the drive train. Under harsh conditions, gear teeth and roller bearings can
break. The foreign objects can damage other components in the drive train. Broken teeth from
other gears and pieces of failed bearings are the two most common types of foreign objects.
Damage from foreign objects must not penetrate the case hardened surface of a gear. The contact
surface of a gear may have only a small amount of damage from foreign objects. Damage from
foreign objects must not exist in the fillets on the gear.
Damage from foreign objects should not exist on the face of the teeth on a gear.
Do not reuse a gear if more than one of the following are true:
Significant amounts of damage from foreign objects on a gear
Damage from foreign objects will affect the distribution of the load.
Damage from foreign objects affects the film of lubrication.
Damage from foreign objects exists in the fillet.
Damage from foreign objects has penetrated the case hardened surface.
Damage from foreign objects is on the threshold of reusing.
Refer to the ""Reconditioning" " section in order to recondition the damage from foreign objects.
If the contact surface near the damage will not become stressed under a normal load, the gear may
be reused.
Illustration 141
The illustration shows the typical example of a planetary gear set. Sun gears and planet gears are external gears. Ring gears are
(35) Ring gears
(36) Sun gears
(37) Planet gears
Illustration 142
Damage from foreign objects (38) is large and deep. The damage is also near the fillet.
Illustration 143
The damage from foreign objects on this gear is just above the pitch line.
Illustration 144
The damage from foreign objects is at the pitch line. Use inspection methods to determine if damage has smooth or sharp
Illustration 145
The damage is at the pitch line and the damage is below the pitch line. The damage that is below the pitch line does not extend into
the fillet. Damage does not show any sharp edges.
Illustration 146
Damage from foreign objects (39) that is next to the pitch line is acceptable. However, because damage (40) extends into the fillet
of the tooth, this gear cannot be reused.
Illustration 147
This illustration is a magnification of Illustration 146. Damage (40) is located in the fillet.
Illustration 148
g01400982
The damage from foreign objects has penetrated the case hardened surface.
Illustration 149
The damage from foreign objects on this tooth exists in the fillet. The damage from foreign objects is shown by the arrow.
Examine the tip of the gear teeth that are meshing for similar damage.
Illustration 150
The tip of the gear teeth that are mating is embedded into the fillet. Do not reuse this gear or the gears that are mating with the
broken tooth. Inspect other gears in the drive train for damage.
Illustration 151
The face of this tooth is severely cracked. Damage from foreign objects can cause a tooth to crack.
Illustration 152
The face of the tooth is severely cracked. The crack is the result of damage from foreign objects. The wide gap that is between
each line of stress and the deep ridges indicates that this crack occurred quickly.
Illustration 153
The severely cracked tips of teeth are the result of damage from foreign objects.
Illustration 154
The deep indentation that is shown on the gear above is from a roller bearing.
Illustration 155
This type of damage from foreign objects was caused by soft debris. Usually, soft debris will not cause a significant amount of
damage.
Damage from Foreign Objects

Note: Gears that have damage from the failures of other parts should be inspected closely due to
the potential of cracking. Use a dye penetrant to check for cracks in the dents that are located on
the teeth.
Illustration 156
The profile of a gear tooth is shown above. The face of the gear tooth is a critical area that should be inspected for damage.
(41) Face of the tooth
(42) Root
Illustration 157
Bruises are seen on the gear tooth. Although the bruises are visible, the bruises do not leave any indentations on the face of the
tooth.
(43) Areas of bruises
Illustration 158
Minor damage from foreign objects exists. Use a dye penetrant to check for cracks in the face of the tooth.
Use the gear again if no cracks are found by using a dye penetrant.
Illustration 159
Damage from foreign objects is seen at the pitch line of the tooth. Use a dye penetrant to check for cracks in the face of the
Illustration 160
Significant damage from foreign objects exists. Use a dye penetrant to check for cracks in the face of the tooth.
THRESH HOLD.
Illustration 161
Significant damage from foreign objects exists on the face of the tooth. The dye penetrant detected a crack in the dent.
Illustration 162
The damage from foreign objects on this gear has not penetrated the case hardened surface. The area of the root in the fillet is not
damaged. Use proper inspection procedures to verify no cracks are present.
THRESH HOLD
Illustration 163
Severe damage from foreign objects exists on the face of the tooth. The dye penetrant detected cracks in the dents.
Rippling
Illustration 164
The gear has damage from rippling that is shown between the lines. This type of damage would be most common on highly loaded
gear teeth.
Illustration 165
Rippling has advanced from scoring to pitting to a change in the profile.
Lipping
Illustration 166
Lipping is the permanent displacement of surface metal. Lipping will happen if a gear is too soft. Lipping will happen if a gear is
overloaded during adequate lubrication. If the lubrication was not adequate, the damage would be a combination of scoring, metal
pullout, and smearing.
Gear Bores
Bores of gears in drive trains are sensitive to damage. If the gear will be reused, the bore must not
have any wear or damage. A good light source is required in order to inspect fully the bore of a
gear.
Refer to ""Cleaning" " in order to clean the bore of the gear. If the gear bore has stains that cannot
be removed with 8T-7765 Surface Reconditioning Pad and solvent, do not reuse the gear. A gear
with minimal damage to the bore can be reused. Make a careful decision on reusing any gear bore
because gear bores are sensitive to damage. If a gear bore has more than one type of damage, the
gear bore should not be reused. Gears with lightly damaged gear bores may be reused if each of
the following conditions are true:
The case hardened surface has not been penetrated.
Damage is light.
Damage is not located in the areas of contact of antifriction bearings.
Damage does not extend across more than 25% of the width of the thrust face.
There are not many damaged areas.
Damage can be smoothed with a 6V-2010 Polishing Stone .
Planetary Gear Bores

Planetary gear bores are unique to other gear bores in drive trains. Planetary gears are highly
loaded. It is important to inspect carefully all planetary gear bores.
Illustration 167
This bore is in excellent condition and there is no visible damage.
Illustration 168
If a gear bore is used as a race for a bearing, the bore should not be worn or damaged. There is no wear or damage in this gear
bore.
Illustration 169
Foreign objects have damaged the bore of this planetary gear.
Illustration 170
g01889867
Examine both edges of the gear.

Notice that the nick is NOT on the bearing surface and has NOT penetrated the case hardening.
Use a 6V-2010 Polishing Stone and oil in order to remove the sharp edges around nick (1) before reusing this gear.
Illustration 171
g01401114
If a bore has stains, clean the bore of the gear. Refer to ""Cleaning" " for more information. If the gear bore is
cleaned and there are still 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
not removed. The discolored lines inside this gear bore are instances of pitting.
Illustration 172
The stains could not be removed from the bore of the gear. The stains are instances of pitting.
Illustration 173
This gear bore has been damaged in both the area of bearing roller track (2) and the area of retaining washers (3) .
Illustration 174
Use good lighting for inspection of any gear bore. If the surface of the bore has an irregular contour, the beams of light will not
straight.
Illustration 175
The washers for retaining bearings have spun inside the gear bore.
Illustration 176
Brinelling will create a hilly appearance and a hilly texture on the surface of the bore. Do not reuse a gear with a bore that has
damage from brinelling.
Illustration 177
This gear bore has corroded. Notice that the corrosion makes a pattern of parallel bands in the bore.
Illustration 178
The bore on this planetary gear has spalled.
Check lube quality, loading, parts alignment.

Illustration 179
The gear bore that is shown in the above illustration has corroded.
Gears with Replaceable Bearing Races

Damage to a bore with a replaceable bearing race occurs when the bearing cup rotates inside the
gear bore. Planetary gears with replaceable bearing races can often be used again if the race has
only crept in the bore. Before reusing the gear, check the size of the gear bore in order to
determine that the bore is still within specifications for reusability. Refer to Reuse and Salvage
Guideline, SEBF8185, "Salvage Procedure for Final Drive Planet Gear Used in Off-Highway
Trucks" for more information about gears that have replaceable bearing races.
Illustration 180
The bearing race has crept inside this bore and the race has caused only a small amount of damage. If the bore is still within the
specifications, the gear may be used again. The dark brown or black appearance may be caused from gear oil and the appearance
can be removed with 8T-7765 Surface Reconditioning Pad and solvent. If the bore is not within tolerance, refer to Reuse and
Salvage Guideline, SEBF8185, "Salvage Procedure for Final Drive Planet Gear Used in Off-Highway Trucks" before installing the
new bearing.
Illustration 181
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 the gear. The blue
color in the bore was caused by extreme temperatures. If a gear bore becomes overheated, the gear cannot be used again.
Spider Gear Bores
Illustration 182
The bore of this gear has spun around a shaft. The bore is beyond the limit for reusing. The teeth are also heavily damaged.
Splines
Splines should be checked for wear with a seal pick. The seal pick should be held perpendicular to
the spline. If the pick is stopped by any of the wear steps, do not reuse the gear. Visually check for
other damage on the spline before reusing the gear. Refer to the Inspecting the Splines section
within Reuse and Salvage Guideline, SEBF8443 for proper Inspection and Measuring procedures.
Illustration 183
Use a seal pick in order to determine if a spline can be reused. Hold the pick in a position that is perpendicular to the spline
that is being checked. Drag the seal pick across wear step (5). If the pick is stopped by the wear step, do not reuse the spline. Fillet
radius (6) is also shown.
(4) Seal pick
(5) Wear step
(6) Fillet radius
Illustration 184
This gear has spline wear that does not stop a seal pick. Check the wear at the ends of the contact between the shaft and the gear
bore. If there is no other damage, the spline may be used again.
Thrust Faces
The thrust face of a planet gear, sun gear, or side gear should not have smears or heat checks. Heat
checks are shallow cracks that interrupt the film of lubrication. Heat checks can shave off material
from the thrust bearing. Gears with light damage on the thrust face can be used again. Light
scratches are acceptable only when the scratches do not stop a seal pick. If there is a sharp edge on
the thrust face, remove the edge with 6V-2010 Polishing Stone and oil.
Illustration 185
The thrust face on this planet gear is in good condition. The gear may be used again if there are no cracks in the surface of the
thrust face. Inspect the gear for cracks with any of the methods for inspecting cracks.
Illustration 186
g01401405
The differential side gear is approaching the wear limit. This gear does not have any other damage so this gear may
be used again. The roughness and damage that is shown by the arrows is the limit for reusability.
Illustration 187
The arrows show the roughness and damage. The complete thrust face does not meet the standards for reusability. Also note the
discoloration.
Copyright 1993 - 2012 Caterpillar Inc.
Thu Mar 1 16:29:40 EST 2012
Todos los derechos reservados.

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771D Truck 6JR00001-00134 (MACHINE) POWERED BY 3408E Engine(SEBP247...

Pautas de reutilizacin y recuperacin

Fecha de publicacin -07/11/2011

Fecha de actualizacin -07/11/2011

Reusability of Drive Train Gears{3002, 3159, 3256, 4055}

Summary of Changes in SEBF8193

Updated Crack Detection Procedure, Reviewed Part Numbers

Update Group Effectivity

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Added Asphalt Paver to Group Effectivity

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

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Improper operation, lubrication, maintenance or repair of this product

This safety alert symbol means:

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Reuse And Salvage Guidelines "Standardized Parts Marking Procedures"

Reuse And Salvage Guidelines "General Salvage and Reconditioning

Reuse And Salvage Guidelines "Index of Repair Process Engineering

Tooling and Equipment

Gear Inspection Stand Gp

Borescope Inspection Group

Crack Detection Kit

Surface Reconditioning Pad

Metal Marking Pen

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Reflective Surface for Inspection

Bright Incandescent Light

Key elements of a gear are identified in Table 4.

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Nomenclature of Gear Teeth

Highest point of single tooth contact (HPSTC)

Lowest point of single tooth contact (LPSTC)

Start of active profile

Pitch diameter of gear

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Straight Bevel Gears

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Case Hardened Surface

Machine Application, Operation, and Maintenance

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Methods for Minimizing Gear Failures

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Operational Characteristics of Gears

Caterpillar Genuine Gears

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Proprietary heat-treat processes

Case Hardened Surface

Rolling Action and Sliding Action

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LPSTC and HPSTC

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LPSTC and HPSTC

Load and Velocity of Contact

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Process for Inspecting Gears

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4. Bearing bores may have minimal wear or damage only.

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