Salvage of Differential Bearing Cage on Off-Highway Trucks {3258, 3283, 3284} Caterpillar

Off-Highway Truck/Tractor

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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.

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, 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.

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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.

References

Service Advisories, Service Letters, and Technical Service Bulletins

The most recent Service Advisories, Service Letters, and Technical Service Bulletins that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Service Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired.

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.

This list of machines and tooling is a recommended list. The salvage procedure can also be completed by using equivalent machinery.

Preparation for Salvage Procedure

The differential bearing cage needs to be thoroughly cleaned to remove all oil, grease, and debris prior to starting the"Salvage Procedure".

Illustration 3	g01287663
Bearing cage after cleaning.

After cleaning, the cage should be measured using inside micrometers to determine the size, the out of round, and the taper of the bore.

Illustration 4	g01287729
Measuring for taper, size and out of roundness.

Illustration 4 is an example of taking measurement at the top of the bore.

Illustration 5	g01287748
Measure the cage at the top and the bottom of bore. Also, measure the cage in various locations around the diameter (90° away from each other).

Illustration 5 is an example of taking a measuring at the bottom of the bore.

Illustrations 4 and 5 give examples of measuring at locations 90° away from each other.

Salvage Procedure

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Illustration 6	g01287794
Bearing cage is being held in the chuck of the lathe.

1. After the cage has been measured, the cage should be put in a lathe for machining. Machine the inside diameter to a cleanup and eliminate any out of round or taper. After machining, clean the cage again.
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   Illustration 7	g01287798
   Bearing cage after cleanup.

2. Measure the inside diameter for size after cleanup.
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   Illustration 8	g01287803
   Protect the threads with aluminum tape before shot blasting.

3. Protect the threads of the bearing cage with aluminum tape. Place the bearing cage in shot blasting equipment and use Aluminum Oxide (20 grit) to prepare the inside diameter for metal spray.

   Note: After shot blasting the inside diameter, the surface should not be touched prior to the application of thermal spray. Oil and grease will contaminate the surface, which will result in reduced adhesion of sprayed powder.

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   Illustration 9	g01287805
   The top surface of the bearing cage is protected for the procedure of thermal spray.

4. Carefully use Oerlikon Metco anti-bond to coat the top face of the bearing cage. This step will eliminate any adhesion of the metal powder to the surface. Make sure that only the top surface is coated.
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   Illustration 10	g01287807
   Metal spray is being applied.

5. Mount the bearing cage in a lathe or on a rotating table. Apply flame spray to the inside diameter of the cage by using equipment for thermal spray. The diameter must be built up to 1.0 mm (0.04 inch) below the mean dimension of the cage.

   Refer to Table 4 for dimensions and tolerances and SEBF2178Reuse and Salvage Guidelines, "Thermal Spray Procedures for OHT Cage - Bearing". for parameters and settings of the equipment for thermal spray.

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   Table 4

   Inside Diameter of Bearing Cage
   Part Number	Description	New Bearing Cage Inside Diameter	Inside Diameter After Thermal Spray	Chamfer Dimensions
   2D-9459	Bearing Cage	Ø 190.564 ± 0.025 mm (7.5025 ± .0010 inch)	Ø 191.580 mm (7.5425 inch)	1.5 mm (0.06 inch) at 30°
   3D-9553	Bearing Cage	Ø 215.964 ± 0.025 mm (8.5025 ± 0.0010 inch)	Ø 216.980 mm (8.5425 inch)	1.5 mm (0.06 inch) at 30°
   5T-5967	Bearing Cage	Ø 268.352 ± 0.025 mm (10.5650 ± 0.0010 inch)	Ø 269.367 mm (10.6050 inch)	1.5 mm (0.06 inch) at 30°
   5T-5966	Bearing Cage	Ø 222.314 ± 0.025 mm (8.7525 ± 0.0010 inch)	Ø 223.330 mm (8.7925 inch)	1.5 mm (0.06 inch) at 30°
   8W-9447	Bearing Cage	Ø 311.240 ± 0.025 mm (12.2535 ± 0.0010 inch)	Ø 312.255 mm (12.2935 inch)	1.5 mm (0.06 inch) at 30°
   105-8584	Bearing Cage	Ø 228.549 ± 0.04 mm (8.9980 ± 0.0016 inch)	Ø 227.533 mm (8.9580 inch)	1.5 mm (0.06 inch) at 30°
   203-3995	Bearing Cage	Ø 225 ± 0.02 mm (8.85825 ± 0.00079 inch)	Ø 211.016 mm (8.3077 inch)	1.5 mm (0.06 inch) at 45°

6. Allow the bearing cage to cool and remove tape from the threads before machining.
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   Illustration 11	g01288733
   Jaws have been bored to correct size.

7. Make sure that jaws of the chuck are bored correctly for the outside diameter of the bearing cage. Machining the jaws of the lathe to the same diameter as the bearing cage will cause equal pressure to be exerted on the outside diameter.
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   Illustration 12	g01287810
   The outside diameter is being checked with a dial indicator.

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   Illustration 13	g01287953
   The face is being checked with a dial indicator.

8. Place the bearing cage in a lathe. Zero set a dial indicator on the outside diameter and the end face. Rotate one revolution to measure total indicator reading. The maximum for the total indicator reading is 0.127 mm (0.0050 inch).
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   Illustration 14	g01288745
   Boring bar is installed on the lathe and ready to make cleanup cut.

9. Use the boring bar and make a cleanup cut.
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   Illustration 15	g01288755
   Machine the bearing cage to the inside diameter of a new bearing cage which is specified in Table 4.

   Note: Care must be taken to control the depth of the boring bar. Do not damage the threads at the bottom of the cut.

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   Illustration 16	g01288925
   Make sure that the depth of the cut does not damage the threads.

10. Use inside micrometers and measure the diameter of the bore. Machine the bore to the inside diameter of a new bearing cage that is given in Table 4.
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    Illustration 17	g01288934
    The edge of the bearing cage should be chamfered and the edge of the bearing cage should be deburred.

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    Illustration 18	g01314756
    The dimensions for the chamfer that are shown above are listed in Table 4. (1) Depth of the chamfer (2) Angle of the chamfer and location of the chamfer

11. Use the boring bar or the tool for chamfering to cut a chamfer on the bearing cage. Deburr the bearing cage and remove the bearing cage from the lathe. Dimensions for the chamfer are shown in Illustration 1 and given in Table 4.