Repair of Pump Drive Gears for Torque Converters {3100, 3101} Caterpillar

Integrated Toolcarrier

All

Landfill Compactor

All

Load Haul Dump

All

Off-Highway Truck/Tractor

770G (S/N: KDH1-UP; ECM1-UP)

777E (S/N: KDP1-UP)

777G (S/N: T5A1-UP; T4Y1-UP)

789C (S/N: 2BW1-UP)

789D (S/N: SPD1-UP; SHH1-UP)

793B (S/N: 1HL1-UP; 4AR1-UP)

793C (S/N: CBR1-UP; ATY1-UP; 4GZ1-UP)

Soil Compactor

All

Track-Type Loader

931C (S/N: 2XK1-UP)

Track-Type Tractor

All

7A (S/N: 72F1-UP)

D5 (S/N: 94J1-UP)

Underground Articulated Truck

All

Wheel Dozer

814 (S/N: 90P1-UP; 14R1-UP)

814B (S/N: 16Z1-UP)

814F (S/N: BGF1-UP; 9DM1-UP)

814F Series 2 (S/N: BXG1-UP)

824C (S/N: 85X1-UP)

824G (S/N: 4SN1-UP)

824G Series II (S/N: AWW1-UP)

824H (S/N: ASX1-UP)

824K (S/N: 2T21-UP; 2L41-UP)

834G (S/N: BPC1-UP; 6GZ1-UP)

834H (S/N: BTX1-UP)

844 (S/N: BBN1-UP; 2KZ1-UP)

844H (S/N: BTW1-UP)

854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)

854K (S/N: 2211-UP; RM31-UP; H9K1-UP; H8M1-UP)

Wheel Loader

All

Wheel Skidder

522C (S/N: 2WL1-UP)

525 (S/N: 1DN1-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 for reuse and salvage procedures of the torque converter drive gear.

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.

Summary

Many pump drive gears for torque converters are damaged because of grooves in the inside bore caused by the seal rings. Most gears can be used again after the worn bores are restored to the original dimensions by hard chrome plating or metal spray. Refer to Illustration 3 that shows a typical torque converter and the location of the pump drive gear.

Gear teeth should be checked for pitting, spalling, or excessive wear. Any sign of these problems indicates that the gear should not be used again.

Illustration 3	g02103613
Typical torque converter and pump drive gear (1)

Note: Illustrations in this guideline may appear different from some of the components. While the illustrations are typical, the dimensions are actual. All the dimensions that are listed are dimensions for manufacturing and assembling a new machine.

References

Use the following references for additional information.

Service Advisories, Service Letters, and Technical Service 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

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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

• Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and oil.

• 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 bore 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.

• Use appropriate thread taps to chase all threaded holes.

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 5	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 6	g03856853
Typical Example

Illustration 6 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 7	g03856857
Typical Example

Illustration 7 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 7. In this example, the gear has a total of 22,000 hours.

Measurement Techniques

A dial bore gauge is the preferred method of measuring bores but if a dial bore gauge is not available, an inside micrometer can be used.

Measurement Tooling include precision inside and outside diameter micrometers capable of measuring four decimal places in inches or three decimal places in millimeters. Measuring tools should be calibrated using gage blocks certified to a national standard such as the National Institute of Standards and Technology (NIST).

Ensure that several sample measurements are taken at different locations on the same feature. Measure diameters of internal bores in several places to identify tapered and or oval conditions.

Gear Inspection

In Illustration 8 through Illustration 12, face (2) and reference bore diameter (A) are used to get correct alignment of the seal ring bore when it is machined. The finished bore diameter is shown in the tables following the illustrations.

Illustration 8	g02103614
(2) Face (A) Reference bore diameter (B) Finished bore diameter (C) Chamfer angle 30° (D) Chamfer width

Illustration 9	g02103774
(2) Face (A) Reference bore diameter (B) Finished bore diameter (C) Chamfer angle 30° (D) Chamfer width

Illustration 10	g02103877
(2) Face (A) Reference bore diameter (B) Finished bore diameter (C) Chamfer angle 30° (D) Chamfer width

Illustration 11	g02105515
(2) Face (A) Reference bore diameter (B) Finished bore diameter (C) Chamfer angle 30° (D) Chamfer width

Illustration 12	g02105593
(2) Face (A) Reference bore diameter (B) Finished bore diameter (C) Chamfer angle 30° (D) Chamfer width

Illustration 13	g06359673
(A) Reference bore diameter (B) Finished bore diameter (C) Chamfer angle 30° (D) Chamfer width

Procedure to Grind Before Plating or Metal Spraying

Use pins between gear teeth to hold the pump drive gear in the chuck of an internal grinder. Zero the gear in the chuck with a Total Indicator Reading (TIR) of 0.05 mm (0.002 inch) on reference bore diameter (A). Refer to Illustrations 8 through 13.

Grind bore (A) to a depth that will remove all indications of surface wear. Remove at least 0.25 mm (0.010 inch) from the diameter before metal spraying. The machined surface must be within 0.05 mm (0.002 inch) TIR of reference bore diameter (A). There must be no indications of grinding errors, such as chattering, heat checks, or burning.

Hard Chrome Plating

Use standard commercial masking plating baths and procedures for the application of chrome plating.

Procedure To Grind Hard Chrome Plating

Note: Refer to Illustrations 8 through 13 for steps 1 through 4 of the "Procedure To Grind Hard Chrome Plating" section.

1. Use pins between the gear teeth to hold the pump drive gear in the chuck of an internal grinder. Zero the gear in the chuck with a TIR of 0.05 mm (0.002 inch) on reference bore diameter (A).

2. Carefully grind the chrome plating to prevent heat or pressure damage to the plating. Use a Norton #32-A-80-K5-VBE or similar aluminum oxide, 80 grit vitrified bond grinding wheel. Use a large volume of cutting fluid of either heavy duty synthetic or light soluble oil. Use wheel speeds of 6500 ft to 8500 ft surface per minute and a medium to high work speed to prevent heat damage. Stock removal must be limited to a maximum of 0.05 mm (0.002 inch) per pass.

3. Grind the chrome plated inside seal ring bore to ñ 0.03 mm (0.001 inch). The ground bore must have a surface texture of 1.6 µm (63 µinch) or smoother. If the above grinding wheel, speed, and feed rate are used, the surface texture will be correct. If it is necessary to measure the surface texture, use a surface texture comparator or a surface texture analyzer. The bore must be concentric (have a common center) with reference bore diameter (A) within 0.05 mm (0.002 inch) TIR and be perpendicular (at a 90 degree angle) to the face of the pump drive gear (refer to Illustration 8 through Illustration 12) within 0.05 mm (0.002 inch).

4. There must be a chamfer at the edge of the bore (refer to Illustration 8 through Illustration 13). This chamfer will permit the seal rings to go into the inside bore.

Metal Spraying

Consult the manufacturer of the metal spray equipment for powder recommendations and machine settings.

Metco Inc. is one manufacturer of acceptable metal spraying equipment and powder. Refer to Reuse and Salvage Guidelines, SEBF9236, "Fundamentals of HVOF Spray for Reconditioning Components", Reuse and Salvage Guidelines, SEBF9238, "Fundamentals of Arc Spray for Reconditioning Components", Reuse and Salvage Guidelines, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components", Reuse and Salvage Guidelines, SEBF9404, "Fundamentals of Plasma Transferred Wire Arc (PTWA) Spray for Reconditioning Components".

Crack Detection Methods

There are four major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Surface Inspection (VT), Liquid Penetrant Testing (PT), and Dry / Wet Magnetic Particle Testing (MPT).

Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, and Dry/ Wet MPT are methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most versatile. For example, the PT method can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using the Wet MPT is more accurate. Refer to Table 10 for advantages and disadvantages and Table 11 for standards and requirements for these NDT methods.

Visual Surface Inspection (VT)

Illustration 14	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

Refer to Tooling and Equipment Table 3 for part numbers.

Components and welds that are to be tested using PT or MPT shall first be subject to a Visual Surface Inspection (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration 14. 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.

Liquid Penetrant Testing (PT)

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetration Oil: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrating oil indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

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Illustration 15	g06084048
Typical example of pre-cleaning the testing area.

1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe the area to be tested with a solvent dampened cloth to remove remaining dirt and allow the area to dry. Remove paint where there are visible cracks using paint remover or a wire brush.
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   Illustration 16	g06084053
   Typical example of applying penetrating oil to areas to be tested.

2. Apply penetrating oil by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrating oil to soak. After the penetrating oil has been allowed to soak, remove the excess penetrating oil with clean, dry wipe.
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   Illustration 17	g06084060
   Typical example of removing penetrating oil with a cloth.

3. The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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   Illustration 18	g06084070
   Typical example of applying the developer.

4. Before using developer, ensure that the developer is mixed thoroughly by shaking the container. Hold the container approximately 203 - 305 mm (8 - 12 inch) away from part. Apply an even, thin layer of developer over the area being tested. A few thin layers are a better application method than one thick layer.
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   Illustration 19	g03773759
   Typical example of cracks found during Liquid Penetrant Testing (PT).

5. Allow the developer to dry completely for 10 to 15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 19. Clean the area of application of the developer with solvent cleaner.

Liquid Penetrant Testing (PT)

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetrating Oil: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrating oil indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

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Illustration 20	g06103795
Typical example of pre-cleaning the testing area.

1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe the area to be tested with a solvent dampened cloth to remove remaining dirt and allow the area to dry. Remove paint where there are visible cracks using paint remover or a wire brush.
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   Illustration 21	g06103803
   Typical example of applying penetrating oil to areas to be tested.

2. Apply penetrant by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrant to soak. After the penetrating oil has been allowed to soak, remove the excess penetrating oil with clean, dry wipe.
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   Illustration 22	g06103816
   Typical example of removing penetrating oil with a cloth.

3. The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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   Illustration 23	g06103820
   Typical example of applying the developer.

4. Before using developer, ensure that the developer is mixed thoroughly by shaking the container. Hold the container approximately 203 - 305 mm (8.0 - 12.0 inch) away from the testing area. Apply an even, thin layer of developer over the testing area. A few thin layers are a better application method than one thick layer.
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   Illustration 24	g06084042
   Typical example of cracks found during Liquid Penetrant Testing (PT).

5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 24. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MPT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 25	g06085930
(A) Indications shown by Dry Magnetic Particle Testing (MPT). (B) Electromagnetic Yoke (C) Dry Powder Bulb

1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.

6. Observe particles and note if any clusters of particles appear revealing an indication.

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MPT)

Materials and Equipment

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 26	g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MPT). (B) Electromagnetic Yoke (D) Ultraviolet Lamp

Illustration 27	g06003178
Pear Shaped Centrifuge Tube

1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.

2. Concentration:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) divisions, refer to Illustration 27. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. The oil shall have the following characteristics:

      • Low viscosity not to exceed 5 mm²/_s (5 cSt) at any temperature at which the vehicle is to be used.

      • Low inherent fluorescence and be non-reactive.

   5. The conditioning agents used in the conditioned water shall have the following characteristics:

      • Impart good wetting characteristics and good dispersion.

      • Minimize foaming and be non-corrosive.

      • Low viscosity shall not exceed a maximum viscosity of 5 mm²/_s (5 cSt) at 38° C (100° F).

      • Non-fluorescent, non-reactive, and odorless.

      • Alkalinity shall not exceed a pH of 10.5.

3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
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   Illustration 28	g03536210

3. For case hardened and ground surfaces:

   • Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 28 for an example of yoke placement.

4. Visually inspect for indications of discontinuities using the proper illumination.

5. Record the size and shape of any discontinuities found.