Salvage of Differential Carriers {3258, 3284} Caterpillar

Articulated Truck

D25C (S/N: 9YC1-UP)

D25D (S/N: 1HK1-UP)

D30C (S/N: 7ZC1-UP)

D30D (S/N: 3AJ1-UP)

D35-HP (S/N: 3FD1-UP)

D350C (S/N: 8XC1-UP)

D35C (S/N: 2GD1-UP)

D400 (S/N: 1MD1-UP)

D400D (S/N: 8TF1-UP)

D40D (S/N: 2JJ1-UP)

D44 (S/N: 2LD1-UP)

D44B (S/N: 8SD1-UP)

D550 (S/N: 4RD1-UP)

D550B (S/N: 5ND1-UP)

Landfill Compactor

816 (S/N: 57U1-UP)

816B (S/N: 15Z1-UP)

826K (S/N: 2L31-UP; 2T61-UP)

836 (S/N: 3RL1-UP)

836G (S/N: BRL1-UP; 7MZ1-UP)

836H (S/N: BXD1-UP; XTR1-UP)

836K (S/N: B8H1-UP; T6X1-UP; L6Z1-UP; LWZ1-UP; TWZ1-UP)

Load Haul Dump

R2900G (S/N: GLK1-UP; JLK1-UP; NLK1-UP)

R3000H (S/N: RCM1-UP; RCY1-UP)

R3200G (S/N: MAZ1-UP)

Soil Compactor

815 (S/N: 91P1-UP)

815B (S/N: 17Z1-UP)

825K (S/N: 2L91-UP; 2T91-UP)

Underground Articulated Truck

AD40 Series II (S/N: 1YZ1-UP)

AD45 (S/N: BKZ1-UP)

AD45B (S/N: CXM1-UP; GXM1-UP)

AD55 (S/N: ANW1-UP; DNW1-UP; GNW1-UP)

AD55B (S/N: JNW1-UP)

AD60 (S/N: KNW1-UP; NNW1-UP)

AE40 Series II (S/N: BLW1-UP; 1ZZ1-UP)

Wheel Dozer

814 (S/N: 90P1-UP)

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

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

834B (S/N: 92Z1-UP)

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

834H (S/N: XDC1-UP; BTX1-UP)

834K (S/N: TW41-UP; L4Y1-UP; LWY1-UP; TWY1-UP)

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

844H (S/N: BTW1-UP)

844K (S/N: MBE1-UP; M4R1-UP; KLS1-UP; K4Y1-UP)

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

854K (S/N: 2211-UP; KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)

Wheel Loader

944 (S/N: 87J1-UP)

944A (S/N: 43A1-UP; 58A1-UP)

950 (S/N: 90A1-UP; 15J1-UP; 49U1-UP)

950B (S/N: 31R1-UP)

966A (S/N: 33A1-UP)

966B (S/N: 75A1-UP)

966C (S/N: 18B1-UP; 9KC1-UP; 78G1-UP; 42J1-UP; 76J1-UP; 30K1-UP; 25U1-UP)

966D (S/N: 7BB1-UP; 6ZC1-UP; 11D1-UP; 35S1-UP; 94X1-UP; 99Y1-UP)

966E (S/N: 2FD1-UP; 35S1-UP; 94X1-UP; 99Y1-UP)

966F (S/N: 4YG1-UP; 8BG1-UP; 7HL1-UP)

966G (S/N: 8XW1-UP)

966R (S/N: 58Z1-UP)

980 (S/N: 42H1-UP)

980B (S/N: 89P1-UP)

980C (S/N: 2EB1-UP; 13B1-UP; 2XD1-UP; 63X1-UP)

980F (S/N: 8CJ1-UP; 3HK1-UP)

980F Series II (S/N: 5XJ1-UP; 4RN1-UP)

980G (S/N: BGC1-UP; 9CM1-UP; 2KR1-UP; 2SR1-UP)

980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)

980H (S/N: PF81-UP; P8B1-UP; MHG1-UP; A8J1-UP; KZL1-UP; JMS1-UP)

980H Series 2 (S/N: MKP1-UP)

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

980L (S/N: D8Z1-UP)

980M (S/N: MK21-UP; WW31-UP; MGD1-UP; XDJ1-UP; KRS1-UP; N8T1-UP)

982M (S/N: WMD1-UP)

986H (S/N: 9861-UP; L8S1-UP)

986K (S/N: MH81-UP; NL81-UP; SWH1-UP)

988 (S/N: 87A1-UP)

988B (S/N: 50W1-UP; 62Y1-UP)

988F (S/N: 8YG1-UP)

988F Series II (S/N: 2ZR1-UP)

988G (S/N: BNH1-UP; 2TW1-UP)

988G Series RTCH (S/N: 1NZ1-UP)

988H (S/N: A7A1-UP; BXY1-UP)

988K (S/N: T8E1-UP; L8X1-UP; LWX1-UP; TWX1-UP)

988K XE (S/N: E8X1-UP; EWX1-UP)

990 (S/N: 7HK1-UP)

990 Series II (S/N: BCR1-UP; 4FR1-UP)

990H (S/N: BWX1-UP)

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)

991K (S/N: 5301-UP)

992 (S/N: 25K1-UP)

992B (S/N: 25K1-UP)

992C (S/N: 42X1-UP; 49Z1-UP)

992D (S/N: 7MJ1-UP)

992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)

992K (S/N: 8801-UP; KK21-UP; RM21-UP; KK41-UP; RM51-UP; H4C1-UP; ZMX1-UP)

993K (S/N: LWA1-UP; Z4D1-UP; Z8D1-UP; Z9K1-UP; Z4Z1-UP; Z8Z1-UP)

Wheel Skidder

528 (S/N: 96C1-UP; 97C1-UP; 51S1-UP; 78W1-UP)

Wheel Tractor-Scraper

613 (S/N: 71M1-UP)

613B (S/N: 5XF1-UP; 38W1-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.

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, 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.

Show/hide table

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.

Summary

This guideline provides the procedures necessary to determine the reusability of the differential group. Life will vary depending on application, load, lubrication, and environment.

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.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to condemn a part from reuse.

The bores and threads for the bearings and bearing retaining nuts, that support the differential gear group in the differential and bevel gear groups, can become worn or damaged to the point that the housing cannot be used again.

Bearing Cap and Bore in Differential Carrier (with Adjustment Ring)

Illustration 3	g06346388

Dimensions of differential carrier with adjustment ring. Refer to Table 2 for dimensions

(1) Dimension X

(2) 5.1 mm (0.20 inch)

(3) Diameter B perpendicular to Diameter A within 0.15 mm (0.006 inch)

(4) 1.5 mm x 45° (.06 inch x 45°)

(5) 1.5 mm x 45° (.06 inch x 45°)

(6) Diameter A

(7) Diameter C

Note: Diameter A is used for a reference to make sure Diameter B is perpendicular.

Bearing Cap and Bore in Differential Carrier (with Bearing Cage)

Illustration 4	g06342441

Dimensions of differential carrier. Refer to Table 3 for dimensions

(1) Dimension X

(2) 5.1 mm (0.20 inch)

(3) Diameter B perpendicular to Diameter A within 0.15 mm (0.006 inch)

(4) 1.5 mm x 45° (.06 inch x 45°)

(5) 1.0 mm C/R (.04 inch) Max.

(6) Diameter A

(7) Diameter C

Note: Diameter A is used for a reference to make sure Diameter B is perpendicular.

Preliminary Cage Fabrication

Illustration 5	g06343474
Bearing cage fabrication. Refer to Table 4 for Dimensions

(15) 1.5 ± 0.5 mm x 45° (0.06 ± 0.02 x 45°)

(16) 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(17) Diameter J concentric with diameter G within 0.05 mm (0.002 inch)

(18) 9.2 mm (0.362 inch) Drill.

(19) 4.06 mm (0.16 inch) Deep.

Carrier Bore Preparation

1. Inspect the joint faces of the carrier bearing cap for wear or damage. Machine the faces flat if necessary.

2. Install the bearing caps and tighten to the torque specification listed in the applicable Disassembly and Assembly manual.

3. Clamp the carrier on the table of a precision boring machine. Find the centerlines of diameter (A) and the bearing bore opposite the one being repaired, to establish the centerline of the new bearing bore.

   Note: If the bore being repaired still has some surface that is not worn, use that surface and the opposite bore to establish the center-line of the new bearing bore, instead of using diameter A.

4. Machine the damaged bore to the dimensions shown in Illustration 5 and Table 4. After machining, the new bearing must be in alignment with the opposite bore within 0.15 mm (0.006 inch).

Cap Preparation

1. Remove the bearing cap.

2. Drill and ream a 7.76 mm (0.305 inch) diameter hole in the cap as shown in Illustration 6

3. Press a 6F-0698 Dowel into the hole. The dowel must extend 4.5 mm (0.18inch) above the surface of the cap.

Illustration 6	g02317022

Cap Modifications

(8) Dimension F

(9) 7.755 ± 0.013 mm (0.3053 ± 0.0005 inch) Diameter 5.0 mm (0.20nch) Deep.

Preliminary Cage Preparation (992C Only)

Note: The following is an optional method for preliminary cage preparation.

1. Clamp a 5T-5966 Bearing Cage on the outside diameter in a lathe. Do not overtighten the jaws.

2. Machine the cage bore for the bearing and cut the threads for the retaining nut. Refer to Illustration 7 for the dimensions

3. Drill a 9.20 mm (0.362 inch) diameter hole, as shown in Illustration 7.

Illustration 7	g02317041
Modifications to 5T-5966 Bearing Cage. Refer to Table 2 for Dimensions.

(10) 240.72 ± 0.13 mm (9.477± 0.005 inch) Diameter.

28.3 mm (1.11 inch) Deep.

9.562 inch - 12 THD

25.3 mm (0.996 inch) Deep.

Thread pitch range : 241.696 mm (9.516 inch) to 241.510 mm (9.508 inch)

(11) 1.5 ± 0.5 mm x 45° (0.06 ± 0.02 x 45°)

(12) 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(13) 240.000 ± 0.040 mm (9.4488 ± 0.0016 inch) Diameter. (Concentric with the outside diameter within 0.50 mm) (0.02 inch)

(14) 9.2 mm (0.362 inch) Drill.

4.0 mm (0.16 inch) Deep.

Final Machining and Assembly

1. If necessary, trim the bearing cage flush with the side of the carrier bore.

2. Machine a slot in the new cage for the nut lock tab. Use the bearing cap as a template.

3. Assemble the differential carrier using standard Service Manual procedures, except as noted in Step 4 (992C)

4. Clean the outside diameter of the bearing cup and inside diameter of the cage with Quick Cure Primer. Apply a thin coat of Bearing Mount to the outside diameter of the cup before final assembly. Be sure that necessary adjustments are made immediately after assembly.