Procedure to Restore Sprocket Shaft Bores in Oval Track-Type Machines{4058, 4164, 4184} Caterpillar

Track-Type Loader:

941 (S/N: 32F1-UP)

941 PS (S/N: 70H1-UP; 80H1-UP)

941 (S/N: 16U1-UP)

941B PS (S/N: 70H1-UP; 80H1-UP)

951 (S/N: 69H1-UP; 79H1-UP; 86J1-UP; 58D1-UP)

951B PS (S/N: 69H1-UP; 79H1-UP; 86J1-UP)

951C PS (S/N: 69H1-UP; 86J1-UP)

955 (S/N: 60A1-UP; 61H1-UP; 64J1-UP; 58D1-UP)

955H (S/N: 60A1-UP)

955K PS (S/N: 61H1-UP)

955K (S/N: 71J1-UP)

955K PS (S/N: 85J1-UP)

955K (S/N: 57M1-UP)

955L PS (S/N: 64J1-UP; 85J1-UP; 13X1-UP; 08Y1-UP)

973D (S/N: LCP1-UP)

977 DD (S/N: 20A1-UP)

977 (S/N: 46H1-UP; 84G1-UP)

977H PS (S/N: 53A1-UP)

977K PS (S/N: 46H1-UP; 48J1-UP; 11K1-UP)

977L (S/N: 48J1-UP)

977L PS (S/N: 11K1-UP; 14X1-UP; 64X1-UP)

977L (S/N: 95X1-UP)

983 (S/N: 38K1-UP)

983B PS (S/N: 58X1-UP)

Track-Type Tractor:

5 (S/N: 84G1-UP)

D4 (S/N: 22C1-UP; 44H1-UP; 20J1-UP; 59J1-UP; 60J1-UP; 61J1-UP; 82J1-UP; 83J1-UP; 84J1-UP; 07R1-UP)

D4C Series II TC/PS (S/N: 7KG1-UP)

D4C Series II LGP TC/PS (S/N: 9BG1-UP)

D4C Series III (S/N: 6YL1-UP)

D4C Series III LGP (S/N: 7SL1-UP; 4LS1-UP)

D4C Series III (S/N: 6BS1-UP)

D4C Series III XL (S/N: 8CS1-UP)

D4C Series III (S/N: 1FW1-UP)

D4C PS (S/N: 1RJ1-UP)

D4C PS LGP (S/N: 2CJ1-UP)

D4D PS (S/N: 22C1-UP)

D4D (S/N: 97F1-UP)

D4D SA DD 60GA (S/N: 44H1-UP)

D4D (S/N: 47H1-UP; 20J1-UP)

D4D PS 60GA (S/N: 59J1-UP)

D4D DD 60GA (S/N: 60J1-UP)

D4D 70GA DD LGP (S/N: 61J1-UP)

D4D (S/N: 65J1-UP; 66J1-UP; 82J1-UP)

D4D PS 60GA (S/N: 83J1-UP)

D4D SA DD 60GA (S/N: 84J1-UP)

D4D PS LGP (S/N: 07R1-UP)

D4D (S/N: 74U1-UP)

D6 DD 74GA (S/N: 46J1-UP)

D6 (S/N: 47J1-UP; 99J1-UP; 10K1-UP)

D6C (S/N: 90B1-UP; 46J1-UP)

D6C PS 74GA (S/N: 47J1-UP)

D6C (S/N: 69J1-UP)

D6C DD 74GA (S/N: 99J1-UP)

D6C PS 74GA (S/N: 10K1-UP)

D6C (S/N: 26K1-UP)

D6C SA DD (S/N: 17R1-UP)

D6C (S/N: 23U1-UP; 24U1-UP)

D6C PS LGP (S/N: 69U1-UP)

D6C (S/N: 49W1-UP)

D7E STD (S/N: MDB1-UP)

D7E LGP (S/N: SCG1-UP)

D7F (S/N: 92E1-UP; 61G1-UP)

D7F DD (S/N: 93N1-UP)

D7F PS (S/N: 94N1-UP)

D7G Series 2 (S/N: 7MB1-UP; 3ZD1-UP; 3GF1-UP)

D7G Series 2 SA DD (S/N: 35N1-UP)

D7G Series 2 (S/N: 64V1-UP; 65V1-UP)

D7G Series 2 DD (S/N: 91V1-UP)

D7G Series 2 PS (S/N: 92V1-UP)

D7G Series 2 (S/N: 44W1-UP; 45W1-UP)

D7G Series 2 PS LGP (S/N: 72W1-UP)

D8 (S/N: 76V1-UP; 77V1-UP)

D8H DD (S/N: 36A1-UP)

D8H (S/N: 46A1-UP)

D8K PS (S/N: 66V1-UP)

D8K DD (S/N: 76V1-UP)

D8K SPL PS (S/N: 77V1-UP)

D9 (S/N: 66A1-UP)

D9 PS DR (S/N: 91J1-UP)

D9 (S/N: 90V1-UP)

D9E (S/N: 50A1-UP)

D9G PS QT (S/N: 66A1-UP)

D9G PS DF (S/N: 90J1-UP)

D9G (S/N: 91J1-UP)

D9H SXS PS RH (S/N: 12U1-UP)

D9H SPL PS (S/N: 90V1-UP)

D9H PS DF (S/N: 97V1-UP)

D9H PS DR (S/N: 98V1-UP)

D9H LH SXS PS (S/N: 99V1-UP)

Introduction

© 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.

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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.

Sprocket Shaft Bore Restoration

Sprocket shaft bores in Oval Track-Type Machines wear and loosen after time during normal machine operation. When that happens, the bores should be restored to original specifications to obtain optimum machine performance.

If the bore is worn evenly and prevents correct assembly of the final drive, the correct method of repair is to build up the taper on the shaft by plating or metalizing. However, when the shaft bore is worn unevenly, it is necessary to bore the bevel gear case and insert a sleeve.

Boring can be accomplished with the 1P-4000 Line Boring Tool Group , shown in Illustration 1. This tool group, used with special pilots which align the boring bar, will produce a bore of sufficient accuracy to extend the service life of the case assembly.

Illustration 1	g02367678
The 1P-4000 Line Boring Tool Group

References

ReferenceSpecial Instruction, SMHS7606, "Use Of 1P4000 Line Boring Tool Group"

Note: The numbering system used in this guideline agrees with Special Instruction, SMHS7606, "Use Of 1P4000 Line Boring Tool Group"

Sleeve, Pilot, and Set Ring Preparation

Pilot Machining

Illustration 2	g02367696
Pilot dimensions (L) Chamfer 3.0 ± 0.5 mm (0.12 ± 0.02 inch) × 45 degree. (M) 50.813 ± 0.013 mm (2.0005 ± 0.0005 inch) dia. (N) Distance 63.5 ± 2.5 mm (2.50 ± 0.10 inch).

Machine pilots from cast iron or mild steel to the dimensions shown in Table 2 and Illustration 2. The pilot with outside diameter (A) is to be used in the outer bore and, the pilot with outside diameter (B) is to be used in the inner bore as shown in Illustration 9.

Sleeve Machining

Illustration 3	g02367918
Sleeve for tapered bore, bore types 1 and 2. (P) 45 degree × 0.76 ± 0.25 mm (0.030 ± 0.010 inch) (Q) 45 degree × 0.76 ± 0.25 mm (0.030 ± 0.010 inch) (R) Saw cut 1.5 mm (0.06 inch) (S) 6.35 mm (0.250 inch)

Illustration 4	g02367919
Sleeve for straight bore, bore type 3. (T) Chamfer 20 degree (U) 45 degree × 1.5 mm (0.06 inch) (V) 2.3 ± 0.2 mm (0.09 ± 0.01 inch)

Refer to Table 3 for dimensions (C), (D), (E), and (F) in Illustration 3 and Illustration 4.

Machine sleeves from mild steel using dimensions (C), (D), (E), and (F) for the tapered bore (Table 5 and Illustration 3) bore types 1 and 2 as shown in Table 3 and Table 5. Use dimensions (C), (D), and (E) (Table 3 and Illustration 4) for the straight bore, bore type (E). The sleeve for the tapered bore should be split to allow the sleeve to expand to a press fit when the shaft is installed.

Taper size for the three types of bores listed in the Table 3 are:

• Type 1 - Taper ream 25.4 mm (1.00 inch) per foot on the diameter.

• Type 2 - Taper ream 38.1 mm (1.50 inch) per foot on the diameter.

• Type 3 - Straight bore.

Micrometer Set Ring Machining

Machine a micrometer set ring from cast iron or mild steel to the dimensions shown in Illustration 5 and Table 4. Stamp the diameter of the ring on the face of the ring for a reference dimension when adjusting the micrometer. The ring is used to set the micrometer in the bracket assembly to 0.76 mm (0.030 inch) less than final bore diameter. This is the point where rough machining cuts will end and finish cuts will begin.

Illustration 5	g02371157
Micrometer set ring machining dimensions (W) 31.8 ± 0.5 mm (1.25 ± 0.020 inch) height (X) 50.813 ± 0.013 mm (2.0005 ± 0.0005 inch) (Y) 45 degree × 3.0 ± 0.5 mm (0.12 ± 0.02 inch) (G) Refer to Table 4.

Tool Setting Procedure

Illustration 6	g02371297
Setting the micrometer (3) Set ring (4) Micrometer (5) Spindle (6) Bolt

1. To initially set micrometer (4) in the bracket assembly, place set ring (3) on the fixture. Adjust the micrometer so it reads the diameter stamped on the set ring and push the micrometer until the spindle (5) lightly touches the ring, then tighten bolt (6). Record this micrometer reading. This reading is the reference diameter where the amount of material removed per boring cut is reduced from a rough cut to a finish cut.

   Note: Since the micrometer registers the diameter that the tool will cut, all dimensions are expressed in amount of material removed from the diameter. Depth of cut is half this amount.

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Illustration 7	g02371360
Tool holders (23) Tool holder (24) Tool holder

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Illustration 8	g02371361
Adjusting the bit (24) Tool holder (25) Rod

2. Place tool holder (23) or (24) on the micrometer bracket assembly. Align the marks on the shaft and the holder. Tighten the holder and set the micrometer to the dimension of the first rough cut listed in Table 5. Turn the micrometer arm so the tip of the bit touches the center of the micrometer spindle. Do not sweep the micrometer spindle across the carbide cutter. Adjust the bit by pushing it lightly with rod (25). Repeat this process after each cut.

3. Remove the tool holder and repeat this process for each boring cut by adjusting the micrometer out 6.35 mm (0.250 inch) for rough cuts and 0.25 mm (0.010 inch) for finish cuts and lightly pushing the bit against the center of the micrometer.

4. An FT1481 Micrometer Holder and 1P2371 Micrometer can be used to eliminate the need to remove the tool holder to reset the boring bit for each cut. Refer to Tool Guide, Section 2 Engine Tools, "Cylinder Block, Liners, and Lube System".

Taper size for the three types of bores listed in the Table 5 are:

• Type 1 - Taper ream 25.4 mm (1.00 inch) per foot on the diameter.

• Type 2 - Taper ream 38.1 mm (1.50 inch) per foot on the diameter.

• Type 3 - Straight bore.

Salvage Procedure for Bevel Gear Case

The following boring procedure should be used along with Special Instruction, SMHS7606, "Use Of 1P-4000 Line Boring Tool Group ".

1. Remove the sprocket shafts. Use a petroleum-based solvent to clean the straight bores where the pilots will be positioned.

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Illustration 9	g02371601
Positioning the pilot in the straight bores (31) Pilot A (32) Pilot B (33) Straight bores

2. Position the pilots in the straight bores (as shown in Illustration 9) being careful not to damage the pilots or bores.

3. Put oil on the boring bar and place it through the pilots. If there is any binding, tap the pilots into alignment until the bar rotates freely.

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Illustration 10	g02371697
Placing the tool holder on the bar.

4. Wipe the boring bar and the tool holder clean. Place the tool holder on the bar, with the bit facing the direction of rotation.

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Illustration 11	g02373336
Angle bracket. (A) Height 76.2 mm (3.00 inch) (B) Distance 76.2 mm (3.00 inch) (C) Distance 177.8 mm (7.00 inch) (D) Distance 22.2 mm (0.87 inch) (E) Distance 38.6 mm (1.52 inch) (F) Width 152.4 mm (6.00 inch) (G) Distance 38.6 mm (1.52 inch) (H) Distance 22.2 mm (0.87 inch) (J) Distance 63.5 mm (2.50 inch) (K) Distance 95.2 mm (3.75 inch) (L) Distance 76.2 mm (3.00 inch) (M) Distance 127.0 mm (5.00 inch) (N) Distance 304.8 mm (12.00 inch) (P) Length 609.6 mm (24.00 inch)

5. Mount the bearing assembly and bridge (refer to (9) and (10) in Special Instruction, SMHS7606, "Use Of 1P4000 Line Boring Tool Group") to the bevel gear case using a 6.0 mm (0.24 inch) thick angle bracket as shown in Illustration 11. The bar must rotate freely as the bearing adjustment screw is tightened to prevent chatter in the bore. Be sure not to tighten the bearing adjustment screw too tight, or excessive heat will build up when bar is power-driven.

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Illustration 12	g02428296
Angle bracket, bridge, bearing, and torsion bar assemblies (34) Torsion Bar Assembly (35) Bridge (36) Angle Bracket (37) Bearing Assembly (38) Holder and Cutter Tip (39) Boring Bar

6. Bolt the torsion bar assembly to the side flange of the bevel gear case. Be sure it will not interfere with the bearing assembly during the boring operation.

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Illustration 13	g02373516
(19) Feed assembly (20) Setscrew

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Illustration 14	g02373517
(18) Bolt (21) Bolt (22) Thumbscrew

7. Install feed assembly (19) onto the boring bar and tighten setscrew (20). Slide the feed assembly onto the torsion bar. Tighten bolt (21) securely and bolt (18) finger tight. The boring bar must slide in and out after this operation is completed. Move the boring bar towards the case until the point of the tool is even with the outside edge of the bore that is to be machined and tighten thumbscrew (22) .

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Illustration 15	g02374656
Adjusting the stop collar to stop the feed mechanism at the correct bore depth. (40) Stop collar locking bolt (J) Refer to Table 6

8. Slide an FT1482 Stop Collar onto the shaft of the feed mechanism. Adjust the stop collar to stop the feed mechanism at the correct bore depth (Dimension (J) from Table 6).

   Note: Do not start the boring operation until the setting is found to be correct. Always double check to make sure that the cutter tip is set at the correct dimension.

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Illustration 16	g02374657
Set the feed mechanism to feed. (28) Lever

9. Set the feed mechanism to feed by turning lever (28) up (direction of arrow).

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Illustration 17	g02374816
Use an ? inch electric drill to feed the tool when oiling. (18) Bolt (19) Feed assembly (31) Pilot A (32) Pilot B (34) Torsion bar assembly (35) Bridge (36) Angle bracket (37) Bearing assembly (38) Holder and cutter tip (39) Boring bar (40) Stop collar locking bolt (41) ? inch electric drill (42) Universal joint (43) Oil bearing assembly (44) Taper bore (45) Case

10. Oil the pilots and the bearing assembly. Do not use lubricant on the cutter. Use an ? inch electric drill with a universal joint to feed the tool (refer to Illustration 17).

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Illustration 18	g02374957
Bore dimensions (Refer to Table 6). (S) Distance 6.4 ± 0.5 mm (0.25 ± 0.020 inch)

11. Bore the case to the dimensions given in Table 6. Be sure to reset the stop collar depth when boring dimension (K). To assure accurate work and prevent excessive stress on the equipment, rough cuts should never exceed 0.64 mm (0.025 inch) on the diameter. Finish cuts should not exceed 0.25 mm (0.010 inch) on the diameter.

12. Once the boring operation has been completed, insert the sleeve in the bore. Install the shaft as per the Service Manual. Tighten the shaft retaining nut as the shaft is driven in. Drill a hole through the nut and shaft (dimensions in Service Manual). Install the pin and lock the ring on the retainer nut. Finally, install the final drive gears, idler pinions, and bearings.

    Taper size for the three types of bores listed in the Table 6 are:

    • Type 1 - Taper ream 25.4 mm (1.00 inch) per foot on the diameter.

    • Type 2 - Taper ream 38.1 mm (1.50 inch) per foot on the diameter.

    • Type 3 - Straight bore.

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    Table 6

    Sleeve Dimensions
    Bore Type	Model	Serial No.	Case Bore ID (H)	Bore Depth (J)	Counterbore ID (K)
    1	D4C D4D	ALL S/N:78A1-7626, ; S/N:22C1-1, ; S/N:20J1-1	87.27 ± 0.02 mm (3.436 ± 0.001 inch)	71.50 ± 1.00 mm (2.815 ± 0.039 inch)	93.713 ± 0.064 mm (3.6895 ± 0.0025 inch)
    2	D4D 941, 941B, 951B, 951C	S/N:78A7627-UP ; S/N:82J1-1, ; S/N:83J1-1, ; S/N:84J1-1 ALL	103.99 ± 0.02 mm (4.094 ± 0.001 inch)	117.48 ± 1.00 mm (4.625 ± 0.039 inch)	110.426 ± 0.064 mm (4.3475 ± 0.0025 inch)
    1	977D 977E	ALL	111.10 ± 0.02 mm (4.374 ± 0.001 inch)	104.78 ± 1.00 mm (4.125 ± 0.039 inch)	123.888 ± 0.064 mm (4.8775 ± 0.0025 inch)
    1	977K, 977L	ALL	116.18 ± 0.02 mm (4.574 ± 0.001 inch)	104.78 ± 1.00 mm (4.12519 ± 0.03937 inch)	125.794 ± 0.064 mm (4.9525 ± 0.0025 inch)
    1	D7, D7C, D7D	ALL	117.45 ± 0.02 mm (4.624 ± 0.001 inch)	111.12 ± 1.00 mm (4.375 ± 0.039 inch)	130.238 ± 0.064 mm (5.1275 ± 0.0025 inch)
    1	D7F, D7G, 983	ALL	152.45 ± 0.02 mm (6.002 ± 0.001 inch)	114.43 ± 1.00 mm (4.505 ± 0.039 inch)	171.564 ± 0.064 mm (6.754 ± 0.0025 inch)
    3	D8H, D8K	ALL	146.05 ± 0.02 mm (5.750 ± 0.001 inch)	92.96 ± 1.00 mm (3.660 ± 0.039 inch)	None
    3	D9E	ALL	165.10 ± 0.02 mm (6.500 ± 0.001 inch)	118.36 ± 1.00 mm (4.660 ± 0.039 inch)	None
    3	D9G, D9H	ALL	187.32 ± 0.02 mm (7.375 ± 0.001 inch)	70.87 ± 1.00 mm (2.790 ± 0.039 inch)	None
    2	955H, 955K, 955L	ALL	98.40 ± 0.02 mm (3.874 ± 0.001 inch)	89.03 ± 1.00 mm (3.505 ± 0.039 inch)	104.838 ± 0.064 mm (4.1275 ± 0.0025 inch)
    1	977H	ALL	111.10 ± 0.02 mm (4.374 ± 0.001 inch)	117.48 ± 1.00 mm (4.625 ± 0.039 inch)	123.888 ± 0.064 mm (4.8775 ± 0.0025 inch)