Brake Drums for Track-Type Tractors and Loaders{4050, 4252} Caterpillar

Pipelayer:

561D (S/N: 54X1-UP)

572G (S/N: 8PC1-UP; 40U1-UP)

583H (S/N: 61A1-UP; 78V1-UP)

583K (S/N: 78V1-UP)

594 (S/N: 96V1-UP)

594H (S/N: 96V1-UP)

Track-Type Loader:

931 (S/N: 08N1-UP; 10N1-UP; 78U1-UP)

931B (S/N: 4SC1-UP; 6EC1-UP; 25Y1-UP; 26Y1-UP; 29Y1-UP; 30Y1-UP)

931C Series 2 (S/N: 9AG1-UP; 6AJ1-UP; 2AK1-UP)

931C (S/N: 6RF1-UP; 7HF1-UP; 8AF1-UP; 5LG1-UP; 2BJ1-UP)

941 (S/N: 80H1-UP)

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

955 (S/N: 61H1-UP; 64J1-UP)

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

955L (S/N: 64J1-UP)

973D (S/N: LCP1-UP)

977 (S/N: 46H1-UP)

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

977L (S/N: 48J1-UP; 11K1-UP; 14X1-UP; 64X1-UP; 95X1-UP)

Track-Type Tractor:

D3 (S/N: 06N1-UP; 79U1-UP)

D3B (S/N: 2PC1-UP; 3YC1-UP; 5MC1-UP; 23Y1-UP; 24Y1-UP; 27Y1-UP; 28Y1-UP)

D3C Series 2 (S/N: 5ZG1-UP; 7JG1-UP; 8DG1-UP; 4HJ1-UP; 5CJ1-UP)

D3C Series 3 (S/N: 6SL1-UP; 7XL1-UP; 4KS1-UP; 4TS1-UP; 5GS1-UP; 9TS1-UP)

D3C (S/N: 3RF1-UP; 6PF1-UP; 7JF1-UP; 8BF1-UP; 5KG1-UP; 1PJ1-UP)

D4 (S/N: 78A1-UP; 82J1-UP; 83J1-UP; 84J1-UP)

D4C Series 2 (S/N: 7KG1-UP; 9BG1-UP)

D4C Series 3 (S/N: 6YL1-UP; 7SL1-UP; 4LS1-UP; 6BS1-UP; 8CS1-UP; 1FW1-UP)

D4C (S/N: 1RJ1-UP; 2CJ1-UP)

D4D (S/N: 78A1-UP; 82J1-UP; 83J1-UP; 84J1-UP)

D5B (S/N: 8MB1-UP; 5LD1-UP; 8HD1-UP; 22X1-UP; 23X1-UP; 24X1-UP; 25X1-UP; 26X1-UP; 43X1-UP; 44X1-UP; 45X1-UP; 46X1-UP; 47X1-UP; 48X1-UP; 49X1-UP; 21Y1-UP)

D5E (S/N: 9RG1-UP)

D6 (S/N: 19B1-UP; 46J1-UP; 47J1-UP; 99J1-UP; 10K1-UP)

D6C (S/N: 90B1-UP; 46J1-UP; 47J1-UP; 69J1-UP; 99J1-UP; 10K1-UP; 26K1-UP; 17R1-UP; 23U1-UP; 24U1-UP; 69U1-UP; 49W1-UP)

D6D (S/N: 19B1-UP; 5YB1-UP; 36C1-UP; 37C1-UP; 38C1-UP; 6HC1-UP; 7XF1-UP; 7YK1-UP; 9FK1-UP; 74W1-UP; 75W1-UP; 03X1-UP; 04X1-UP; 05X1-UP; 06X1-UP; 19X1-UP; 20X1-UP; 30X1-UP; 31X1-UP; 32X1-UP; 33X1-UP; 01Y1-UP)

D6E (S/N: 8FJ1-UP)

D6G Series 2 (S/N: C6G1-UP; P6G1-UP; BWJ1-UP; 2MJ1-UP; 3SR1-UP; C6X1-UP; P6X1-UP)

D6N (S/N: LJR1-UP)

D6R (S/N: S6T1-UP; S6X1-UP; S6Y1-UP)

D6T (S/N: KSB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; TSM1-UP; WLM1-UP; PLR1-UP; JRW1-UP; RCW1-UP)

D7F (S/N: 92E1-UP; 61G1-UP; 93N1-UP; 94N1-UP)

D7G Series 2 (S/N: 7MB1-UP; 3ZD1-UP; 3GF1-UP; C7G1-UP; 35N1-UP; 64V1-UP; 65V1-UP; 91V1-UP; 92V1-UP; 44W1-UP; 45W1-UP; 72W1-UP)

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

D8H (S/N: 46A1-UP)

D8K (S/N: 76V1-UP; 77V1-UP)

D8T (S/N: MLN1-UP; FCT1-UP)

D9 (S/N: 66A1-UP; 90V1-UP)

D9G (S/N: 66A1-UP)

D9H (S/N: 12U1-UP; 90V1-UP; 97V1-UP; 98V1-UP; 99V1-UP)

Introduction

© 2012 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.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

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.

Summary

Brake drums may possibly be reused by using certain salvage procedures. The contents of this Guideline should be used as aids in determining the reusability of track-type tractor and track-type loader brake drums. Included in this Guideline are visual inspection criteria, and techniques to machine and measure worn brake drums.

Always correct any conditions that have caused the original failure and never install a part that fills within the "Do Not Use Again" criteria. All brake drums that are to be used with new linings need machining to be assured of the correct surface roughness to provide adequate braking.

Visual Inspection

Illustration 1	g02271079
Brake drum with a crack in the outer surface. Do not use again unless crack is removed during machining. See "Procedure to Machine Brake Drums".

Illustration 2	g02271097
Deep grooves caused by wear. Use again after the brake drum is machined and measured. See "Procedure to Machine Brake Drums"and "Procedure to Measure Brake Drums".

Illustration 3	g02271100
Brake drum is smoother than 3.2 µm (125 µ inch) and shows some smearing and wear. Use again after the brake drum is machined to the correct surface finish of 32. to 4.1 µm (125 to 160 µm).

Illustration 4	g02272154
Change of color ( blue) on the inner splines caused by high heat on the outside of the drum. The surface of this type of drum will have hard areas which may make the drum difficult to machine properly. Use again only after the area is annealed and machined. "Procedure to Anneal"and "Procedure to Machine Brake Drums".

Procedure To Machine Brake Drums

Work Hardened Bands

Inspect brake drum bands to determine that bands are not work hardened (see Illustration 5). Work hardened bands are the result of high heat, caused by the brake band coming in contact with the brake drum during braking.

Hardness can be difficult to determine if the drum has much smearing or heavy wear. One sign of hardness is a change of color (normally blue) on the inner splines. If a hardness tester is used, compare between worn and non-worn areas.

If any area of the brake drum is work hardened, anneal the brake drum according to "Procedure to Anneal" before machining. If no area of the brake drum is work hardened, machine the brake drum as follows.

Illustration 5	g02272214
Work hardened bands which will not machine flat is an indication that the drum was not annealed before the band was machined. Use again after the drum is annealed and machined. See "Procedure to Anneal" and "Procedure to Machine Brake Drums".

Machining Brake Drums

Install the brake drum in a horizontal or vertical lathe. Do not use force on the chuck as force will cause brake drum distortion.

Use a dial indicator to check the amount of T.I.R. (Total Indicator Reading) on the inner circumference and on the brake drum flange. Make sure that the brake drum is perpendicular (at a 90° angle) to the cutting tool and concentric (has a common center) with the lathe centerline (see Illustrations 6 and 7). If the drum has been annealed, this check will also show if there was any distortion of the drum during the anneal procedure. The runout (T.I.R.) must be 0.127 mm (.005 inch) or less (see Illustrations 8 and 9).

The run-out for the final machined surface for all brake drum sizes must be 0.254 mm (.010 inch) or less in relation to the flange face and the inside bore. Use a dial indicator on the drum outside diameter to check runout. To cut the outside diameter, use a rigid setup for the cutting tool. For smaller drums, a long boring bar is acceptable (see Illustration 10).

Illustration 6	g02272275
Make sure that the flange face is perpendicular to the rotation of the lathe chuck. (Illustrations 6 and 7)

Illustration 7	g02272315

Illustration 8	g02272336
Check to make sure that the drum is concentric with the inside bore.

Illustration 9	g02272457
Check to make sure that the drum is concentric with the inside bore. The runout must be less than 0.127 mm (.005 inch).

Illustration 10	g02272577
A brake drum on a horizontal lathe with a boring bar (used as the cutting tool).

The specifications in Table 2 give the needed machined surface finish of 3.2 to 4.1 µm (125 to 160 µ inch). Use an American Standard (A.N.S.I.) tool, a TNMG-432, C-2 Grade Carbide Cutter, with a 0.762 mm (.030 inch ) tip radius. Table 2 also lists feed and speed rates needed for drums with different diameters. Do not machine more than the "Use Again" diameter units given in Table 2.

During the machining procedure:

1. Remove enough material so that a minimum of 80% of the brake drum outside diameter is a newly machined surface. Some small groves are acceptable, however, all small cracks must be removed by the machining process.

2. Use vernier calipers to measure the outside diameter of the brake drum. If this dimension is not smaller than the minimum drum diameter, the drum can be used again.
   Show/hide table

   Table 2

   Specifications To Machine Track-Type Tractor Brake Drums
   Depth Of Cut: 0.381 mm (.015 inch) Feed Per Revolution: 0.165 mm (.0065 inch) Surface Finish: 3.2 to 4.1 µm (125 to 160 µ inch)
   Model	Typical Brake Drum Part Number	Outside Diameter (New)	"Used Again" (Minimum Diameter)	Lathe Speed (RPM)
   D3, D3B, D3C, D4C, 931, 931B, 931C	6S-3203	330.15 mm (12.998 inch)	326.97 mm (12.873 inch)	70
   D4D, D4E, 941, 941B, 955L, 955K	7K-8237	330.15 mm (12.998 inch)	326.97 mm (12.873 inch)	70
   D5B	8P-0203	425.45 mm (16.750 inch)	422.27 mm (16.625 inch)	55
   D6C, D6D, D6E, D6E, D6G, D6N, 973D, 977, 977K, 977L	2S-7603	425.45 mm (16.750 inch)	422.27 mm (16.625 inch)	55
   D6N, D6T, D8T	136-1595	353.56 mm (13.919 inch)	350.38 mm (13.795 inch)	55
   D7F, D7G, 572G, 983, 983B	5M-1998	425.45 mm (16.750 inch)	422.27 mm (16.625 inch)	55
   D8H, 583H	8H-2434	447.68 mm (17.625 inch)	444.50 mm (17.500 inch)	50
   D8K, 583K	2P-9038	447.68 mm (17.625 inch)	444.50 mm (17.500 inch)	50
   D9G, D9H, 594H	2M-6984	501.65 mm (19.750 inch)	498.48 mm (19.625 inch)	45

Procedure to Anneal

This procedure makes iron softer by the application of heat.

1. Heat the drum in an oven to a temperature between 400 and 485°C (750°F and 900°F) for approximately 1 minute.

   Note: Using a blow torch to heat the drum is NOT recommended because of the possibility of brake drum distortion. If a blow torch has been used, the drum must be checked for distortion while still installed in the lathe.

2. Allow the drum to cool to room temperature. (Using water to cool the drum can cause stresses in the drum.)

3. Use 8T-3195 Temperature Recorder Group Crayons or a pyrometer to check the temperature

Procedure To Measure Brake Drums

After the procedure to machine, use vernier calipers to measure the drum diameter (see Illustration 11 and Table 2).

Illustration 11	g02276433
Measuring the outside diameter of the brake drum with vernier calipers after machining the drum.