Brake Drums for Off-Highway Trucks, Tractors, and Scrapers {0762, 4008, 4250, 4252} Caterpillar

Articulated Truck

D25C (S/N: 9YC1-UP)

D25D (S/N: 1HK1-UP)

D300D (S/N: 5MG1-UP)

D30C (S/N: 7ZC1-UP)

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

D350C (S/N: 8XC1-UP)

D35C (S/N: 2GD1-UP)

D400 (S/N: 1MD1-UP)

D400D (S/N: 8TF1-UP)

D44B (S/N: 8SD1-UP)

D550B (S/N: 5ND1-UP)

Off-Highway Truck/Tractor

769 (S/N: 35W1-UP)

769B (S/N: 99F1-UP)

769C (S/N: 01X1-UP)

773 (S/N: 63G1-UP)

773B (S/N: 63W1-UP)

777 (S/N: 84A1-UP)

Wheel Tractor-Scraper

611 (S/N: 6SZ1-UP; 7WZ1-UP)

615 (S/N: 46Z1-UP; 47Z1-UP)

615C (S/N: 5TF1-UP)

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

621 (S/N: 2DB1-UP; 37G1-UP; 23H1-UP)

621B (S/N: 6XB1-UP; 7KC1-UP; 8HC1-UP; 9AC1-UP; 45P1-UP; 31V1-UP; 35V1-UP; 36V1-UP; 73V1-UP)

621E (S/N: 6AB1-UP; 6BB1-UP; 2PD1-UP; 2TF1-UP)

621F (S/N: 4SK1-UP; 5JK1-UP; 8PL1-UP; 9NL1-UP)

621G (S/N: DBB1-UP; MSE1-UP; ANG1-UP; KLK1-UP; NEL1-UP; CEN1-UP; ALP1-UP; CEP1-UP; KJW1-UP; DBX1-UP)

621R (S/N: 12Y1-UP)

621S (S/N: 8KD1-UP)

623B (S/N: 61E1-UP)

623E (S/N: 6CB1-UP; 6DB1-UP; 6YF1-UP; 5SG1-UP)

623F (S/N: 6BK1-UP; 3XW1-UP; 5EW1-UP)

627 (S/N: 50K1-UP; 54K1-UP; 68M1-UP; 69M1-UP)

627B (S/N: 14S1-UP; 15S1-UP; 32V1-UP; 33V1-UP; 34V1-UP; 37V1-UP; 38V1-UP; 56V1-UP)

627E (S/N: 6EB1-UP; 6FB1-UP; 6GB1-UP; 6HB1-UP; 7CG1-UP; 3WJ1-UP)

627F (S/N: 4YK1-UP; 1DL1-UP)

630A (S/N: 60F1-UP)

630B (S/N: 10G1-UP)

631B (S/N: 11G1-UP)

631C (S/N: 28F1-UP; 67M1-UP)

631D (S/N: 24W1-UP; 28W1-UP; 29W1-UP; 39W1-UP)

631E (S/N: 1AB1-UP; 1BB1-UP; 4LD1-UP)

631E Series II (S/N: 1NB1-UP; 6PC1-UP; 3ND1-UP)

633B (S/N: 86H1-UP)

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

633D (S/N: 19W1-UP; 25W1-UP)

637 (S/N: 64M1-UP; 65M1-UP; 91N1-UP; 92N1-UP; 79P1-UP)

637D (S/N: 4JB1-UP; 20W1-UP; 21W1-UP; 22W1-UP; 23W1-UP; 26W1-UP; 27W1-UP; 70W1-UP; 71W1-UP)

639D (S/N: 88X1-UP; 99X1-UP)

651 (S/N: 23G1-UP; 33G1-UP; 44M1-UP)

651B (S/N: 67K1-UP; 45M1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP; 88Z1-UP; 89Z1-UP)

657 (S/N: 19G1-UP; 31G1-UP; 46M1-UP)

657B (S/N: 47M1-UP)

657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

666 (S/N: 64H1-UP)

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

Introduction

© 2019 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.

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, be sure 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 illustrations in this guideline should serve as aids in determining if brake drums can be used again. Salvage procedures include machining worn drums for use with oversize brake linings. This guideline also includes procedures to measure brake drums.

References

Service Advisories, Service Letters, and Technical Service Bulletins

Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

Inspection

Illustration 3	g02952257
Off-highway truck and tractor-scraper brake drums.

Always correct any conditions that have caused the original failure and never install a part that falls within the DO NOT USE AGAIN criteria.

Illustration 4	g02174917
Brake drum with crack in the outer surface.

DO NOT USE AGAIN

Illustration 5	g02174950
Brake drum surface with open cracks that can be felt with a fingernail or pencil lead.

DO NOT USE AGAIN

Illustration 6	g02174925
Brake drum with elongated bolt holes and a fretted (wear of material between two contact parts due to continuous, small amount of relative movement) flange.

OK TO USE PART AGAIN

Illustration 7	g02174927
Brake drum with nicks and grooves in the flange face. Remove the sharp edges and high spots of the nicks and grooves with a file or a 6V-2010 Polishing Stone.

OK TO USE PART AGAIN

Illustration 8	g02174937
Brake drum with smeared areas on the brake surface, but no wear.

OK TO USE PART AGAIN

Visual Inspection

If a brake drum has visible wear or fine cracks in the brake surface, the brake drum must be measured to see if the brake drum can be machined. For all scraper models, except the 615, use the brake drum gauge to measure the diameter of the brake drum at three places, 60° apart, near both ends of the worn area. The ends of the gauge must be perpendicular at (90° angle) to the brake surface. If there are grooves in the brake surface, measure the deepest groove. The drum can be machined if the mark on the gauge rod is visible in the opening of the gauge tube at each of the places that were measured. Refer to the "Procedure To Machine Brake Drums" section in this Guideline.

The drums for the 615 Scraper can be measured with an inside micrometer or caliper to determine if the drums can be used again. However, oversize linings are not available to permit machining of the drum. The dimension for the drum for the 615 Scraper, shown in Table 1, is the maximum allowable diameter and does not include allowance for any additional wear.

Illustration 9	g02174956
Measurement of brake surface diameter with brake drum gauge.

Illustration 10	g02174959
Close-up of the brake drum gauge

If the brake drum Gauge is unavailable, measure the diameter of the drum and compare with the “Use Again Maximum Diameter” shown in Table 4.

Illustration 11	g02174986
Typical example of brake drum with wear and fine cracks. Measure the brake surface diameter.

Illustration 12	g02174989
Brake drum with wear, fine cracks, and notches. Measure the brake surface diameter. If the notches are not removed when the drum is machined, use an emery cloth or a polishing stone to make the edges of the notches smooth.

Procedure To Machine Brake Drums

The following procedure will give the needed machined surface of 3.2 µm (125 µinch) or better.

Getting Started

Install the brake drum in a horizontal or vertical lathe. Use a dial indicator to check the amount of run-out on the outer circumference of the brake drum flange and the flange face to make sure that the brake drum is perpendicular (at a 90° angle) and concentric (having a common center) to the boring tool. Do not apply too much force to the chuck. Excessive force will distort the brake drum.

Tools Needed

Refer to Table 5 for the feeds and speeds.

1. Remove only enough material from the brake drum bore so at least 80% of the bore is a new machined surface. If there are fine cracks in the brake drum bore, the drum must be machined to remove the cracks.

2. Use the brake drum gauge to measure the brake drum diameter. If the mark on the gauge rod can be seen in the opening of the gauge tube,OK TO USE THE BRAKE DRUM AGAIN.

   • If the mark on the gauge rod is between the lines on the tube in the space marked “STD” use the standard brake linings.

   • If the mark on the gauge rod is between the lines on the tube in the space that had the mark “.12 O.S.,” use 3.18 mm (0.125 inch) oversize brake linings.

   • If the mark on the gauge rod is between the line and the edge of the opening in the space that has the mark “.25 O.S.,” use 6.35 mm (0.250 inch) oversize brake linings.
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   Illustration 13	g02175038
   Brake drum with grooved wear. Measure the brake surface diameter.

3. If the brake drum gauge is not available, measure the diameter of the drum. If the diameter of the brake drum is more than the “Maximum Diameter” shown in Table 4, then DO NOT USE THE BRAKE DRUM AGAIN.If the diameter is less than the “Maximum Diameter,” use standard or oversize linings as shown in Table 5.
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   Illustration 14	g02175124
   Example of measuring the new surface to verify it is concentric to the outer circumference of the flange.

4. Put a small chamfer on both ends of the bore. Check the new surface to see if it is concentric to the outer circumference of the flange. Use a micrometer to measure the distance from the outer circumference of the flange to the brake surface. Measure at six places, 60° apart. The difference between the largest and smallest measurement must not be more than 0.25 mm (0.15 inch).

Use a square and a thickness gauge to verify that the bore is perpendicular to the face of the flange. Measure at six places, 60° apart, across the length of the bore. The gap measurement must not be more than 0.25 mm (0.010 inch).

Illustration 15	g02175132
Measure the face of the new surface.

Note: All dimensions are mm (in).