Motor Grader Circle Pinion Reuse {5207} Caterpillar

Motor Grader

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Introduction

© 2017 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.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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 provides the procedures that are required to evaluate the reusability of circle pinions for motor graders. This guideline allows Caterpillar dealer personnel to determine the reusability of a circle pinion accurately. The information that is provided in this guideline can also be submitted to a customer to ensure that proper reusability guidelines are being followed. Part numbers that are affected by this guideline are shown in Table 2.

Often, circle pinions may be reused even if significant wear is evident.

This guideline contains the latest standards that will help minimize owning and operating costs. Parts that meet the specifications in this guideline can be expected to give normal performance until the next scheduled overhaul. Do not install a part that should not be used again according to this guideline. Any condition that might have caused the original wear to occur should be corrected during the repair procedure.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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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 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Service Letters and Technical Information Bulletins

Tooling and Equipment

Table 3 contains the items that are needed to complete the repair procedures in this guideline.

Prepare the Area for Inspection

Illustration 3	g00008666

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Illustration 4	g03721203
Typical burr removal tooling. (A) Right Angle Die Grinder (B) Die Grinder (C) ( D) ( E) Conditioning Discs, Disc Pad Holder, and Threaded Shaft (F) ( G) Flapper Wheels

• Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of an unacceptable defect.

• When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all lifting devices must be inspected before use.

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

• If the component cannot be inspected immediately after cleaning, put hydraulic oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.

Considerations for the Reusability of Circle Pinions

The circle pinion is a ductile iron casting with six gear teeth. On a motor grader, the pinion is meshed with the circle drive to rotate the blade. During normal operation of the circle drive and circle pinion, pinion wear will occur. The circle drive is a hardened steel component. Therefore, most wear will be restricted to the circle pinion. Wear on the circle pinion is normal. Wear on the circle pinion that is kept within the specifications suggested in this guideline will not have a detrimental effect on the operation of the machine. A significant amount of wear can occur before the circle pinion must be removed and replaced with a new pinion.

To determine reusability of the circle pinion, the following must be considered:

• The width of the individual lands of the teeth on the pinion gear

• The gear tooth wear must be even on each side of the teeth.

Measure the individual lands of the teeth on a pinion gear by using vernier calipers. The minimum width of the lands is 2.0 mm (0.08 inch).

Note: The profile of a new gear is shown in Illustration 6. As wear occurs, the gear develops a land in the tooth. The width of the land on the tooth is defined as the width of the remaining as cast material.

Illustration 5	g01841253
(1) Circle (2) Circle Pinion

Illustration 6	g01841453
When the drive gear of the circle pinion is new, the profile of the gear tooth is rounded. This is shown in Illustration 6.

Illustration 7	g01841475
Dimension (A) shows the width of remaining as cast material. The critical dimension in determining the reusability of a circle pinion is the width of the remaining as cast material. Measure the width of the remaining as cast material to determine the reusability of the circle pinion.

Note: When wear occurs, individual gear teeth may exhibit various widths of lands. A difference in the width of the remaining as cast material of 2.0 mm (0.08 inch) to 4.0 mm (0.16 inch) is acceptable. The variation between the width of the lands of individual gear teeth that is more than 4.0 mm (0.16 inch) may indicate a misaligned circle. When an inspection of the circle pinion is occurring, the circle adjustment should be evaluated. Refer to the appropriate Testing and Adjusting manual for your machine.

Procedure for Inspection of the Circle Pinion

1. All safety precautions must be followed before measuring the pinion.

2. Clean the circle pinion, removing any lubrication and debris prior to completing the measurement procedure.
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   Illustration 8	g01841494
   Dimension (A) is the width of the remaining as cast material.

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   Illustration 9	g01841513
   Procedure for measuring the circle pinion

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   Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the engine is running unless otherwise specified.

3. Use a vernier caliper to measure dimension (A) for each tooth. Dimension (A) is the width of the remaining as cast material. Dimension (A) must be equal to or greater than 2.0 mm (0.08 inch).

   Note: The width of the remaining as cast material should be measured from the top point of gear tooth contact on each side of the gear tooth. Refer to Illustration 8 and Illustration 9.

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   Illustration 10	g01841574
   Uneven wear is evident on the circle pinion. Evaluate the circle adjustment. If the uneven wear is significant, do not reuse the pinion.

4. Inspect the gear teeth for even wear on both sides. If one side of a gear tooth has greater wear than the other side, evaluate the circle adjustment. Refer to the appropriate Testing and Adjusting manual for your machine.

5. Complete an evaluation of the circle adjustment. If the circle is misadjusted, realign the circle by using the appropriate procedure. Refer to the appropriate Testing and Adjusting manual for your machine.

Examples of Reusability of Pinions

The following examples will assist dealer personnel in determining whether a circle pinion may be reused. The width of the remaining as cast material of the gear teeth should be measured carefully. Refer to the "Procedure for Inspection of the Circle Pinion" section of this manual to measure the teeth.

Illustration 11	g01841616
Circle pinion with low hours and no significant wear

USE THIS PART AGAIN.

Illustration 12	g01841630
(4) A wear step is evident on the gear teeth and is normal to have a wear step. Adhesive surface wear in the form of galling is evident. (A) Dimension (A) is greater than 2.0 mm (0.08 inch), so the pinion may be reused.

USE THIS PART AGAIN.

Note: A reusable pinion gear may also exhibit various types of wear. If any of these types of wear are present, the alignment of the circle and lubrication of the pinion should be evaluated. The gear may be reused in most instances even with the following types of wear.

• Scoring or galling from abrasive wear may be present particularly if insufficient lubrication has been applied.

• Scratches and pits from abrasive wear may be present due to fine abrasive material in the film of the lube or insufficient lube.

Note: Do not apply the criteria for reusability of a circle pinion to any other gear. The application of the circle pinion is different from a typical transmission, final drive, or any other type of gear.

Illustration 13	g01841673
Illustration 13 shows an enlarged view of the tooth in Illustration 12.

Scratching, pitting, and some adhesive wear is evident on the tooth in Illustration 13. The width of the land on the tooth is greater than 2.0 mm (0.08 inch). The pinion may be reused.

Example of a Reusable Circle Pinion

Illustrations 14 through 20 show typical gear tooth wear on the individual teeth of a circle drive pinion. The width of the individual gear teeth is shown in Table 5. The width of the lands on the gears that are shown in Illustrations 14 through 20 is greater than 2.0 mm (0.08 inch). The pinion in this example may be reused.

In Table 5, the Maximum and Minimum measurements of the lands vary more than 2.0 mm (0.08 inch) to 4.0 mm (0.16 inch). The alignment of this circle drive and pinion may be suspect and the pinion should be evaluated. Refer to the appropriate Testing and Adjusting manual for your machine. If the alignment of the circle is deemed acceptable, the pinion may be reused.

Illustration 14	g01841713

The gear teeth that are shown in Illustrations 15 through 20 are identified in Illustration 14 above. The Minimum width of the land on the gear tooth is 3.0 mm (0.12 inch). The Maximum width of the land on the gear tooth is 10.5 mm (0.41 inch). The alignment of the circle should be evaluated due to the variation in wear on the teeth of the gears.

Illustration 15	g01844675
The pinion gear (1) has a 10.0 mm (0.39 inch) width of the land of the remaining as cast material. The wear is even on both sides of the gear tooth. This type of wear is acceptable.

USE THIS PART AGAIN.

Illustration 16	g01844694
Pinion gear (3) has a 5.0 mm (0.20 inch) width of the land of the remaining as cast material. The pinion may be used again. Pitting, scoring, or abrasive wear is evident on the contact surfaces of the gear tooth.

USE THIS PART AGAIN.

Illustration 17	g01844874
Pinion gear (4) has a 3.0 mm (0.12 inch) width of the land of remaining as cast material. This is indicated by dimension (A). The pinion may be used again.

USE THIS PART AGAIN.

Illustration 18	g01844878
Pinion gear (5) has a 5.5 mm (0.22 inch) width of the land of remaining as cast material. This is indicated by dimension (A). The pinion may be used again.

USE THIS PART AGAIN.

Example of a Circle Pinion that is not Reusable

A circle pinion may not be reused if any of the gear teeth have wear that has progressed to a sharp edge. The minimum width of the land of remaining as cast material is 2.0 mm (0.08 inch). Abrasive wear and adhesive wear may be evident on the contact surfaces of the gear tooth.

If the gear tooth wear has progressed to less than 2.0 mm (0.08 inch), the pinion gear should be replaced. When the pinion is replaced, ensure that the circle is aligned properly. Appropriate Disassembly and Assembly procedures should be followed. Refer to the appropriate service manuals.

Illustration 19	g01844915
A circle pinion with excessive gear tooth wear is shown. Width of the land of the remaining as cast material is less than 2.0 mm (0.08 inch). The wear is even. This indicates that the circle is properly aligned. This gear should not be used again.

DO NOT USE THIS PART AGAIN.

Illustration 20	g01844974
Illustration 20 shows a side view of the tooth that is pictured in Illustration 19. Excessive wear is evident in the form of adhesive and abrasive wear. Some pitting, scoring, and galling is evident. Wear steps are visible.

DO NOT USE THIS PART AGAIN.

Note: The width of the land must be measured to determine if the gear that is shown in Illustration 19 and Illustration 20 can be reused. The reusability of the part was not affected by the adhesive wear or the abrasive wear.

Illustration 21	g01845054
The width of the land of the remaining as cast material on the tooth is 0.40 mm (0.016 inch). Therefore, the pinion should not be used again.

DO NOT USE THIS PART AGAIN.

Illustration 22	g01845057
The width of the land of the remaining as cast material on the gear tooth is less than 2.0 mm (0.08 inch). Therefore, this pinion may not be reused.

DO NOT USE THIS PART AGAIN.

The pinion that is shown in Illustration 21 and Illustration 22 has uneven wear on the contact surfaces of the gear teeth. The uneven wear is due to a misaligned circle drive. During installation of a new pinion, the alignment of the circle drive must be evaluated. Refer to the appropriate service manual.

In addition to the uneven wear, the variation in the width of the land was 4.0 mm (0.16 inch). If at least one gear tooth has width of the land of less than 2.0 mm (0.08 inch), the circle pinion may not be reused.

Lubrication

The life of the circle pinion depends on lubrication. Adequate lubrication of the circle pinion and circle will greatly extend the life of the pinion. The circle pinion and the circle need to be adequately lubricated in all operating conditions. Refer to the appropriate Operation and Maintenance Manual.

Note: The circle pinion and the circle should be lubricated in sandy operating conditions. Field tests have proven that pinions that receive adequate lube have extended component life.

Illustration 23	g01845178
(5) Teeth of the blade circle (6) Teeth of the circle drive pinion

1. Clean the dirt and the old lubricant from the blade circle (5) and from the teeth of the circle drive pinion (6).

2. Use 183-3424 Water and Temperature Resistant Grease to apply lubricant to blade circle (5). Also, use 183-3424 Water and Temperature Resistant Grease to apply lubricant to teeth of the circle drive pinion (6).