797 Transmission Planet Shaft Plug Removal, Clean Planet Shaft Lube Passages and Install New Plug Procedures {0599, 0700, 0722, 3160} Caterpillar

Off-Highway Truck/Tractor

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

Introduction

© 2018 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 the Numerical Part Record (NPR) on the Service Information System Website (SIS Web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Note: This document can be used to remove plug or rivet part number 358-7783, clean planet shaft lube passages and install a new Plug of the 797 transmission planet shaft assembly Cat part numbers 445-8995, 445-8998, 446-1232, 446-1331, 446-1335, and 446-1337.

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”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

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

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

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

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

Summary

The 797 uses a sealing plug or rivet style plug in the planet shaft assembly which is unique to that of most of the other planet shaft assemblies. This guideline provides the procedures necessary to remove the plug from the planet carrier shaft to clean lube passages properly. The 797 uses a plug in the planet shaft assembly which is different than most other planet shafts. Life will vary depending on application, load, lubrication, and environment.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part meets the specifications within this guideline and the part is intended for a similar application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to condemn a part from reuse. Follow visual inspections and the "Visual Surface Inspection Method" section for further guidance.

References

Service Advisories, Service Letters, and Technical Service Bulletins

Information

Illustration 3	g06297334
(A) Transmission Arrangement (1) Planet Shaft Assembly (TR1) (2) Planet Shaft Assembly (TR1) (3) Planet Shaft Assembly (TR2) (4) Planet Shaft Assembly (TR3) & (TR4) (5) Planet Shaft Assembly (TR5) (6) Planet Shaft Assembly (TR6

Tooling and Equipment

Note: The Tooling and Equipment in Table 4 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for scope of work to be performed for each specific rebuild.

Preparation Recommendations

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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.

Note: Clean exterior of the 797 transmission prior to disassembly to minimize cross-contamination.

• 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.

• During cleaning and handling, do not damage any of the shaft machined surfaces.

• Use pressurized air to dry the shaft.

Note: The tanks for dipping should be covered when parts are not being coated.

• Dip shaft in SAE 30 TDTO (Transmission/ Drive Train Oil) to prevent rust or corrosion if inspection is not done immediately after cleaning. Spraying or brushing coating on does not sufficiently cover the surfaces of the shaft lube passages. Carefully store the parts in a clean container.

Storage Instructions:

Note: Ensure that preparation recommendations are completed before storage instructions.

• Dip shaft in SAE 30 TDTO (Transmission/ Drive Train Oil) to prevent rust or corrosion if inspection is not done immediately after cleaning. Carefully store the parts in a clean container.

• Once coated, the shaft should be wrapped in a Volatile Corrosion Inhibitor (VCI) paper. VCI paper is recommended. Seal the shaft in a plastic bag. The wrapped shaft should be stored in a clean, dry place.

• Utilize a storage box to protect the shaft and prevent handling damage. Caterpillar recommends using the same boxes and packaging that are used to ship the new shaft.

Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part. Use a metal marking pen to mark the code onto the component.

Illustration 4	g06124077
DO NOT use numbering stamp punches to mark internal components.

The procedure for marking components is a Cat 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.

Example 1

Illustration 5	g03856853
Typical Example

Illustration 5 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.

Example 2

Illustration 6	g03856857
Typical Example

Illustration 6 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 gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 6. In this example, the gear has a total of 22,000 hours.

Example 3

Illustration 7	g03519882
Typical Example

(A) Mark the planet pin on either end using a metal marking pen.

Planet Shaft Plug Removal Procedure

Note: All Illustrations within the "Planet Shaft Plug Removal Procedure" are of planet shaft assembly (1) and can be applied to planet shaft assemblies (2), (3), and (4) due to similarity in design.

1. Use a suitable vice with non-marring v- blocks to secure the planet shaft.
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   Illustration 8	g06297139
   Example of a planet shaft assembly (1) section view. (A) Mandrel Head (B) Sleeve (C) Lube Passage (1) Planet Shaft Assembly (TR1) (5) Plug

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   Illustration 9	g06297188
   Typical Example

2. Use a suitable punch and hammer to punch mandrel head (A) out of sleeve (B) and into lube passage (C) of the planet shaft.
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   Illustration 10	g06297216
   Typical example of exposed ID of sleeve (B) after mandrel head has been punched in. (B) Sleeve

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   Illustration 11	g06297212
   Typical Example (D) Slide Hammer Puller (E) Screw Tip

3. Use slide hammer puller (D) with screw tip (E) to thread into sleeve (B). Refer to Tooling Table 4 for applicable tooling.
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   Illustration 12	g06297221
   Typical Example (B) Sleeve (E) Screw Tip

4. Once screw tip (E) is threaded into sleeve (B) then, use the slide hammer puller to remove sleeve (B) from the lube passage of the planet shaft.

5. Remove the mandrel head from the lube passage.

Clean Planet Shaft Lube Passage Procedure

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Illustration 13	g06297297
Typical Example (C) Lube Passages

1. Ensure that lube passages (C) are clear of any obstructions.

2. During cleaning and handling, do not damage any of the shaft machined surfaces.
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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.

3. Use pressurized air to dry the shaft.

   Note: The tanks for dipping should be covered when parts are not being coated.

4. Dip shaft in SAE 30 TDTO (Transmission/ Drive Train Oil) to prevent rust or corrosion if inspection is not done immediately after cleaning. Spraying or brushing coating on does not sufficiently cover the surfaces of the shaft lube passages. Carefully store the parts in a clean container.

Planet Shaft Plug Installation Procedure

Note: All Illustrations within the "Planet Shaft Plug Installation Procedure" are of planet shaft assembly (1) and can be applied to planet shaft assemblies (2), (3), and (4) due to similarity in design.

1. Use a suitable vice with non-marring v- blocks to secure the planet shaft.
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   Illustration 14	g06297247
   Typical example of plug (5) installation tooling options. (A) Mandrel Head (B) Sleeve (F) Stem (G) Pneumatic Rivet Hand Tool (H) Rivet Tool (5) Plug

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   Illustration 15	g06297277
   Typical example of plug (5) installation. (A) Mandrel Head (B) Sleeve (1) Planet Shaft Assembly (5) Plug

2. Ensuring that plug (5) is fully seated into lube passage (C) of the planet shaft, use a suitable rivet tool to install plug (C).

Visual Surface Inspection Method

Visual Surface Inspection (VT) is a method for testing components for cracks without damaging the component. Refer to Table 5 for advantages and disadvantages and Table 6 for standards and requirements for these NDT methods.

Visual Surface Inspection (VT)

Illustration 16	g06124166
Example of Visual Surface Inspection (VT) Tooling (A) Flashlight (or adequate light source) (B) Magnifying Glass (C) Tape Measure (or other measuring device) (D) Inspection Mirror

Illustration 17	g06085442
Illustration of view through eye piece of a pocket microscope.

If necessary use a microscope with light for enhanced view and to measure the defects. Refer to Tooling Table 4 for the part numbers.

Visual Surface Inspection (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration16 or optional 17. Personnel performing VT shall either be trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. Personnel performing VT shall take routine eye exams.