Procedure to Salvage Tang Slots on Transmission and Brake Pistons {0679, 3160, 4011, 4251} Caterpillar


Procedure to Salvage Tang Slots on Transmission and Brake Pistons {0679, 3160, 4011, 4251}

Usage:

769C 01X
Articulated Truck
All
Asphalt Paver
All
Backhoe Loader
All
Challenger
All
Engine
G3512 (S/N: A3S1-UP; A3T1-UP)
G3516 (S/N: A3X1-UP)
Integrated Toolcarrier
All
Landfill Compactor
All
Motor Grader
All
Off-Highway Truck/Tractor
All
On-Highway Transmission
All
Paving Compactor
All
Petroleum Transmission
All
CX38-P892 (S/N: B4R1-UP)
Pipelayer
All
Pumper All
Utility Mounted
Skid Steer Loader
All
Soil Compactor
All
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Transmission
All OEM Transmissions
TH55FT-E70 (S/N: PCJ1-UP)
TH55FT-E90 (S/N: THE1-UP)
Underground Articulated Truck
All
Wheel Dozer
All
Wheel Feller Buncher
All
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All

Introduction

Table 1
Revision  Summary of Changes in SEBF8178 
08  Added Tables 2and tools in Table 3. Updated effectivity and boilerplate information. 
07  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018.
Removed old point of contacts.
Added new point of contact. 
06  Updated effectivity for All OEM Transmissions and added Canceled Part Numbers and Replaced Part Numbers section. 
05  Update Media with Group Effectivity 
04  Update to SIS web Authored Format 

© 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 1g02139237

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.

------ WARNING! ------

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 2g00008666

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

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.

During normal operation, wear occurs in the slots of transmission and brake piston tangs. Just as the slots become worn on clutch plates, the slots of the piston tangs also become indented on one or both sides. Refer to Illustration 4. This wear causes unnecessary circumferential movement that could cause an interference with the housing resulting in incorrect shifting or braking.

Refer to Table 4 for wear limits in the pin slots.

References

Table 2
References 
Media Number  Publication Type & Title 
Channel1  "Why Reuse and Salvage Parts" 
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
PERJ1017  Special Publication
"Dealer Service Tools Catalog" 
SEBD0512  Reuse and Salvage Guidelines
"Caterpillar Service Welding Guide" 
SEBF8187  Reuse and Salvage Guidelines
"Standardized Parts Marking Procedures" 

Service Advisories, Service Letters, and Technical Service Bulletins


NOTICE

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


NOTICE

Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components.

To avoid component damage, follow the recommended procedure using the recommended tools.


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.

Table 3
Required Tooling and Equipment 
Part Number  Description  Designation 
(1)  Personal Protective Equipment (PPE)  Personal Protection 
367-9109  Caliper (Digital) (6-Inch)  Measurement
Checks 
423-4373  Caliper - Digital
0 - 200 mm (0.0 - 8.00 inch) 
Measurement
Checks 
1U-5516  Disc (Coarse)  Surface
Preparation
/ De-burring 
1U-5518  Threaded Shaft  Surface
Preparation
/ De-burring 
1U-5519  Holder (Disc Pad)  Surface
Preparation
/ De-burring 
222-3076  Die Grinder
(Right Angle) 
Surface
Preparation
/ De-burring 
222-3074  Wheel Grinder Group  Surface
Preparation
/ De-burring 
—  1/4 inch Shank Carbide Burring Bit  Surface
Preparation
/ De-burring 
9U-7377 (2)  Metal Marking Pen  Parts Marking 
6V-2010  Polishing Stone  Gear Polishing 
1U-9918  Brush  General Cleaning 
1U-5512  Abrasive Material (Roll)  General Cleaning 
8T-7765  Surface Reconditioning Pad (180 Grit)  General Cleaning 
162-5791  Towel  General Cleaning 
288-4209  Paper Towel  General Cleaning 
(3)  Bright Incandescent Light  Visual Surface
Inspection (VT) 
—  Degreaser  Weld Preparation 
233-8145  Vise
(4.00 inch) 
Weld Preparation 
4C-3750  Jaw Cap  Weld Preparation 
—  Weld Electrode Ø 2.00 (0.078 inch) Diameter  Welding 
—  Reaction Pin
Ø 15.88 mm (0.625 inch) 
Gauge Weld Repair 
—  Ø 2.70 mm (0.500 inch)  Gauge Weld Repair 
8H-8581  Feeler Gauge
0.038 - 0.635 mm (0.0015 - 0.0250 inch) 
Gauge Weld Repair 
(1) Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
(2) Available in the United States only.
(3) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.

Pin Slot Wear



Illustration 3g02159962


Illustration 4g06398914
Nomenclature for pin slot wear limits

Table 4
Pin Slot Wear Information  Measurements taken 
Reaction Pin Diameter  Slot Width (A)
Maximum 
Radial Indent Width (B)
Maximum 
Actual (A)
Measurement 
Actual (B
Measurement 
Ø 2.70 mm (0.500 inch)  16.3 mm (0.64 inch)  9.7 mm (0.38 inch)     
Ø 15.88 mm (0.625 inch)  19.3 mm (0.76 inch)  9.7 mm (0.38 inch)     

Preparation


NOTICE

Ensure that the jaw caps are in place to prevent damaging the face of the piston.


Thoroughly clean and de-grease the piston. Secure the piston in the vise. Use the die grinder and bit to buff the worn surface of the pin slot, prior to welding.

Salvage Procedure



    Illustration 5g02159964
    Worn Area


    Illustration 6g02159973
    Welded Area

  1. Position the piston with the worn side of the slot downward. Use weld electrode to build up the worn area. Do not put an excessive amount of weld in the slot, higher than the unworn area. Refer to Illustrations 5 and 6.


    Illustration 7g02159974
    Slot ground flush with unworn surface.


    Illustration 8g02159975
    Completed piston with parallel sides.

  2. Use the die grinder and bit to grind the weld flush with the unworn surface of the tang. Grind both sides of the tang and slot area. The ground surface in the pin slot should be parallel with the other side of the slot. The shot width should approximately be 0.25 mm (0.010 inch) to 0.38 mm (0.015 inch) larger than the reaction pin diameter. Refer to Illustrations 7 and 8.

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