- Caterpillar Products
- All Cat Engines
Introduction
| Revision | Summary of Changes in SEBF9364 |
| 02–03 | Added new serial number prefixes. |
| 01 | Created and Authored Document and also made Engine, Hydraulic, and Drivetrain revisions |
| 00 |
© 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 not 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.
Important Safety Information
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| 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 not recommended by Caterpillar is used, ensure the safety of yourself and others. Ensure that the product will not be damaged or 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.
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| 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.
Introduction
This program reviews the current marketing philosophy at Caterpillar regarding parts reuse with dealer management to obtain dealer commitment to:
- 1. Conduct a Scrap Barrel Analysis, and
- 2. Implement parts reuse where applicable.
The program includes four parts:
- 1. Dealer Principal/Top Management meeting.
- 2. Dealer Service Management meeting.
- 3. Scrap Barrel Analysis.
- 4. Dealer meeting to discuss results of the Scrap Barrel Analysis.
Dealer Principal/Top Management Meeting
The Parts and Service Sales Representative and the Service Representative present this meeting to the dealer top management.
The PSSR will present and discuss parts reuse using the presentation entitled, “The Role Parts Reusability Plays in Product Support.” The presentation reviews the marketing philosophy at Caterpillar regarding parts reusability. The presentation will require about 20 minutes.
The SR will then present the Scrap Barrel Analysis Orientation presentation. The orientation reviews the procedures involved to conduct a Scrap Barrel Analysis and the results of previous studies. The orientation will require about 30 minutes to present, plus a discussion period.
The meeting will conclude with a commitment by the dealer to conduct a Scrap Barrel Analysis that will result in dealer implementation of parts reuse guidelines.
Dealer Service Management Meeting
This meeting is presented by the SR to Dealer Service Management after the commitment to conduct a Scrap Barrel Analysis has been established. It includes the following which should be discussed during this meeting:
- 1. The Scrap Barrel Analysis Orientation.
- 2. Parts Collection and Storing.
- 3. Tool Requirements.
- 4. Personnel Selection.
- 5. Work Area Requirements.
- 6. Material Requirements.
- 7. Scrap Barrel Analysis Procedure Discussion.
Scrap Barrel Analysis
This analysis should be conducted by the SR for the dealer personnel who make decisions regarding the reuse of parts. The analysis includes:
- 1. The Scrap Barrel Analysis Orientation.
- 2. Review of Dealer Activity Prior to the Time for the Scrap Barrel Analysis.
- 3. Organize Stored Iron for Evaluation.
- 4. Conduct the Evaluation Procedures.
- 5. Record Data in the Analysis Sheets later in the document..
- 6. Tabulate Data.
Dealer Meeting to Discuss Results of the Scrap Barrel Analysis
This meeting is presented by the SR to selected dealer management and service personnel. The purpose of the meeting is to report the summary information resulting from the Scrap Barrel Analysis. It should include:
- If appropriate, pertinent information previously presented during the orientation.
- Summary information.
- A conclusion which includes:
- Questions, answers, and discussion.
- Goals discussion.
Dealer Principal Meeting - Scrap Barrel Analysis Results
If appropriate, review the Scrap Barrel Analysis procedures and the orientation information.
Present the summary information from the Scrap Barrel Analysis and open a discussion period.
Present your observations regarding the Scrap Barrel Analysis. Discuss things relating to the implementation of reusability guidelines such as company philosophy, tool availability, and condition, shop equipment and procedures, and customer acceptance. Discuss the dealer goals for implementation.
Scrap Barrel Analysis
The Service Representative conducts this analysis. The time required to complete the analysis is 1-1/2 to two days.
Preceding the start of the Scrap Barrel Analysis, check the following:
- That a sufficient quantity of pistons, liners, valves, transmission plates, and discs are available.
- All tools are available and in serviceable condition.
- Personnel have been selected.
- Work area and meeting room is ready.
Parts, tools, and materials are ready for use. The analysis should start with a meeting to discuss reusability guidelines and procedures. The orientation slide presentation is suggested to discuss the development and credibility of the guidelines. Review the Scrap Barrel Analysis procedures.
- Discuss the Guideline for Reusable Parts for:
- Pistons and Cylinder Liners, SEBF8049 and SEBF8068.
- Valves and Valve Springs, SEBF8002.
- Transmission Clutch Plates and Discs, SEBF8013.
- Transmission Clutch Plates and Disc Assemblies with F37 Clutch Friction Material, SEBF8031.
- Reuse of Drivetrain Gears, SEBF8193.
- Discuss the analysis sheets for pistons, liners, valves, transmission plates, and discs. Cover the following:
- The critical areas to be checked.
- The tools to be used and their operation.
- The information to be recorded.
- The data tabulation.
- Answer questions regarding the Scrap Barrel Analysis procedures.
- Proceed to work area to start the evaluation process.
- Organize procedures and assign duties so the analysis progresses in an efficient manner. Example: transmission and engine specialists should be assigned procedures in their area of interest. Organize stored parts for evaluation.
Parts Collection and Storing
At least 50 liners, 50 pistons, 100 valves, 50 transmission plates, and 50 discs must be collected. Parts must be handled carefully and stored in covered containers to prevent damage. In Previous Scrap Barrel Analyses, many parts were not reusable because of damage caused by improper handling, rust, and corrosion.
Tool Requirements
The following tools must be available and in usable condition:
- Appropriate Piston Ring Groove Gauges.
- 1P-3537 Dial Bore Gauge Group includes 1P-3535 Dial Bore Gauge and 2P-3536 Size Setting Fixture Group.
- Valve Thickness Fixture.
- Feeler Gauges
- 0 to 1 in micrometer with 1/10,000 graduations.
- Nylon brush for cleaning liners.
- Piston ring expanders.
- (.006 in) diameter wire or (.006 in) feeler gauge.
- Glass bead cleaning equipment.
- Valve grinder.
- 1/2 inch drill.
- Surface plate or transmission housing for measuring discs and plates.
- Valve stem diameter gauge (6V-0087)
- Detergent washing powder (Do not use liquid detergent).
Personnel Selection
The Scrap Barrel Analysis is an ideal training exercise for service personnel, supervisors, and others who are involved with the decision of reusing parts. The procedures can accommodate 10 persons or more if desired. Determine the number that should participate and organize the procedures to meet the personnel requirements. Persons who influence customer reuse decisions should also be included.
Work Area Requirements
The work area should be conducive to good training procedures. It must include worktable space that will accommodate the parts to be inspected plus a suitable inspection area. A minimum of two work tables having an approximate area of 3 x 6 feet should be provided. The area must be convenient for cleaning equipment, valve grinder, and a portable tool power source (air and electricity) and have adequate lighting for inspection.
Material Requirements:
Reusability Guidelines
Scrap Barrel Analysis Sheets
Shop Towels
Flash lights
Containers for solvent and water. Electrical extension cords.
Power source (electrical extensions and air supply hose).
Seal Pick
Scrap Barrel Analysis Procedure Discussion:
At this point in the meeting, the dealer service personnel should be informed about the procedures involved. Review the above items to ensure proper collection and storing of parts, that tools are acquired and in usable condition, that the right personnel are selected, that the work area is satisfactory, and the necessary materials will be available when needed. The “critical areas to be checked” listed on the analysis sheets for pistons, liners, valves, transmission plates, and discs should be discussed as well as the process to follow for recording and tabulating the data.
- Group all pistons together.
- Record the total number of pistons.
- Demonstrate the first step of visual inspection.
- Have the group inspect all pistons and discard ones that are visually not reusable.
- Measure the piston ring groove with go no-go gauges and discard ones that fail to meet the specifications.
- Remove rings and clean pistons using a glass bead cleaner. Make sure the pressure and head size of the cleaner is correct.
- Complete another visual inspection of pistons.
- Remove burrs in ring groove with triangular file.
- Record total reusable pistons.
- Group all liners by bore size on the bench.
- Record total number of liners.
- Demonstrate visual inspection and reject liners as needed.
- Inspect bores for scoring, pitting, and grooving.
- Measure liner ID wear using the 1P-3535 Dial Bore Gauge
- Reinspect bores.
- Record total reusable liners.
- Group valves on bench
- Record number of valves to be inspected.
- Demonstrate visually the inspection of valves.
- Measure valve stem diameter.
- Clean valves using glass bead method.
- Visually inspect valves and measure questionable valve lip thickness.
- Grind valves (check for wear).
- Measure valve lip thickness.
- Record total reusable valves.
- Group all transmission plates on the bench by size.
- Record total number of plates that will be inspected.
- Demonstrate and visually inspect all plates.
- Measure tang wear.
- Check for warp and dish on surface plate or housing.
- Check to determine if core is ableto be remanufactured.
- Deglaze plate as indicated in the Guideline.
- Record reusable and remanufactured plates.
- Group all transmission discs on the bench.
- Record total number of discs.
- Demonstrate and visually inspect all discs.
- Check thickness of F37 discs only.
- Measure for warp and dish on surface plate or housing.
- Deglaze disc as indicated in the Guideline.
- Record total number of reusable discs.
- Summarize the recorded information.
- Calculate the % of reusable parts in each category.
- Calculate the total reusable parts $ by category using average part cost.
- Calculate the total parts dollars inspected and reusable.
- Calculate the overall percent of parts that were inspected that are reusable.
- Calculate the amount of time required to inspect each part.
- Calculate the price of the part vs. cost inspection time.
Critical Areas Checked
____ Crater cracks around heat plug.
____ Top and sides of crown.
____ Cast band for piston rings.
____ Skirt.
____ Piston ring groove wear (using gauges).
____ Remove old rings.
____ Glass bead cleaning and reinspection - including edge.
Tools
- Glass bead machine (50 to 100 micron beads)
- Piston ring groove gauges for both rectangular and keystone type piston rings.
- Piston ring removal tools.
- Pieces of (.006in) diameter wire (34 gauge).
- Triangular file.
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Pistons (continued)
- Crater cracks around heat plug.
- Crack is wider than (.006in).
- Cracks are connected by other cracks.
- Cracks extend into valve pocket.
- Cracks across area between valve pockets.
- Top and sides of crown.
- Marks from valve contact.
- Metal particles imbedded in top of piston.
Show/hide table
Table 3 Use Again After Rework Discard Light carbon scratches Deep carbon scratches
- Cast band for piston rings.
If the correct gauge goes into the raw groove, the piston is worn enough to prevent reuse. However, if the correct gauge does not go into the groove but the ring has free rotation, the piston is reusable.
- Separation.
- Circumference crack.
- Check four places around the circumference.
- If the piston passes the first test, clean with the glass bead machine.
- Before retesting, remove any material which may have been pushed into the piston groove (use triangular file).
- Skirt.
- Small scratches indicate normal wear.
- Damage due to lack of lubrication (must be glass beaded prior to reuse).
- Seizure marks - Discard that is, metal has been pulled from the surface of the metal.
- Small scratches caused by dirt or carbon.
- Glass bead prior to reuse.
- If metal or dirt particles become imbedded in the piston skirt, it may not be reused.
- Pin bore has damage.
- Check for cracks.
- Damage to snap ring groove.
Critical Areas Checked
____ Scoring, rust, or pitting on walls.
____ Ridge indicating excessive wear.
____ Excessive external pitting or damage.
____ Flange.
____ O-ring seal grooves.
____ Wear (using dial bore gauge).
____ Final cleaning (using soap, water, and nylon brush).
Tools
- Dial bore gauge.
- Nylon cleaning brush.
- Soap and water solution.
- Electric drill ( for crushes).
- Strong inspection light (to inspect line walls).
- 8S-2251 Hand Drill (Modified) to check for external pitting.
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Liners (continued)
- Scoring, rust, or pitting on walls.
- Certain amount of pitting is acceptable.
- Excessive pitting will cause a part to be discarded. (Refer to photographs in Guideline.)
- Do not use liners if inside has pits, groove, or others.
- Bore.
- Size ( 6V-7898 Dial Bore Gauge).
- Ridge.
- Flange.
- Chipped - Discard.
- Chipped - Discard.
- Thickness ( 6V-7059 Micrometer)
- Erosion.
- O-ring seal grooves.
- Chips.
- Cracks.
- Erosion.
- Nylon brush.
- Do use with solvents (soap and water only).
- Protective coating.
- Engine oil.
Valve Analysis Sheet.
Critical areas checked:
____ Head and face.
____ Fillet area.
____ Stem (for damage or discoloration).
____ Retainer grooves.
____ Stem diameter/necking.
____ Glass bead cleaning and reinspection.
____ Grind valve, check for warp.
____ Grind retainer end, if needed.
____ Measure lip thickness.
Tools:
- Glass bead machine (50 to 100 micron beads).
- Micrometer (0 to 1 inch).
- Valve grinding machine. (check reuse guide to determine if the valve is regrindable.)
- 5P-6518 Fixture Group (to measure lip thickness).
- 6V-0087 Valve Stem Diameter Gauge.
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Valves (continued)
- Head and face.
- Large or deep marks on wear edge of valve head make them unusable.
- Small marks not deeper than part number stamp near center, reuse.
- A small amount of erosion is okay. Scrap valves with excessive erosion (SEBF8002).
- Chipping... more than .010 in, scrap valve.
- Damage (SEBF8002), scrap valve.
- All valves must be ground even if wear cannot be felt. After grinding, inspect lip thickness.
- As valve turns in grinder - check for warp or bend.
- Grind valves wet.
- Must be no pits or grooves.
- Fillet arm.
- Look for cracks.
- Bond breakdown valve head and valve face.
- If a nick, scratch, or burr can be felt with a fingernail, scrap it.
- Erosion, scrap it.
- Rust by itself is no problem.
- If rust covers pits, scale, and erosion, scrap valve.
- Foreign material, scrap valve.
- Stem.
- Discoloration must not extend into the retainer groove area.
- Erosion, scrap.
- Surface rust, clean and reuse.
- Small marks or scratches which are not deeper than the part number stamp are acceptable.
- Marks with a raised sharp edge, scrap valve.
- Grooves, if you can feel it with your fingernail, scrap it.
- Stem scuffing or seizure, scrap it.
- Valve stem necking scrap it.
- Valve stem burring, scrap it.
- Measure wear (micrometer or 6V-0087, set micrometer on minimum valve).
Clutch Plate Analysis Sheet
Refer to Reuse and Salvage Guidelines, SEBF8014, "Identification and Applications of Transmission Clutch Plates and Specifications to Machine Reaction Faces for Power Shift Transmissions" and Reuse and Salvage Guidelines, SEBF8257, "Procedure to Salvage the Slots for the Pin and Holes for the Reaction Dowel in Transmission Clutch Plates, Pistons, and Housings".
Critical Areas Checked:
____ Tang - tang wear.
____ Reaction surface wear and grooving.
____ Discoloration indicating excessive heat.
____ High spots/thickness differences.
____ Glazing and smearing.
____ Warp and dish flatness.
____ Use of emery polishing cloth for “deglazing”.
____ Reconditioning (grinding) of salvageable plates.
Tools:
- Large surface plate (or flat clutch housings same sizes as plates being inspected).
- Thickness (“feeler”) gauges.
- 6 inch ruler.
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
- Tang wear.
- Pin slot wear less than (.19in) or (3/16in).
- Cracks or breaks.
- Reaction face wear and crowning.
- Excessive wear, scrap.
- Wear recondition and reuse.
- Wear out to a point where the original grind marks show.
- Circumferential grooves, reuse after reconditioning.
- Circumferential marks, must keep discs and plates matching, otherwise recondition.
- Discoloration
- Blue black, scrap.
- Lt brown or Lt blue, recondition.
- High spots.
- Plates that show a shiny surface and/or a smeared surface in the area of the tang should be checked for thickness.
- Difference in thickness must not be more than the specifications found in Reuse and Salvage Guidelines, SEBF8014, "Identification and Applications of Transmission Clutch Plates and Specifications to Machine Reaction Faces for Power Shift Transmissions".
Friction Disc Analysis Sheet
Refer to Reuse and Salvage Guidelines, SEBF8013, "Transmission Clutch Plates and Disc Assemblies with Sintered Bronze Friction Material", Reuse and Salvage Guidelines, SEBF8031, "Transmission Clutch Plates and Disc Assemblies with F37 and F37X Friction Material", Reuse and Salvage Guidelines, SEBF8098, "Transmission Clutch Plates and Disc Assemblies with Rayflex Friction Material", and Reuse and Salvage Guidelines, SEBF8115, "Transmission Clutch Plates and Disc Assemblies with Cellulose Friction Material".
Critical Areas Checked:
____ Tooth wear, cracking.
____ Glazing and smearing.
____ Excessive erosion or chipping.
____ Warp and dish (flatness).
____ Use of emery polishing cloth for “deglazing”.
____ Thickness check (discs of F37 Clutch Friction Material only).
Tools:
- Large surface plate (or flat clutch housings same sizes as plates being inspected).
- Thickness(“feeler” gauges.
- 5P-8557 Disc Thickness Gauge (for discs of F37 clutch friction material).
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Drivetrain Gear Inspection
Refer to Reuse and Salvage Guidelines, SEBF8193, "Reusability of Drive Train Gears"
Critical Areas Check:
____ Tooth wear (seven wear types)
____ Bore wear (seven wear types)
Tools:
- Flashlight
- Seal Pick
- Loupe
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Bearing Area
Lubrication Port
Piston
Tools:
Flashlight
Lapping Plate
Pencil Lead or Pick
Micrometer (measure thickness of slipper)
Dial Indicator (to measure end play between piston and slipper)
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Outer surface
Splines
Tools:
Pencil Lead
Light
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Grooves/wear steps
Heat Cracks
Scratches
Corrosion Pitting
Tools:
Light
Pencil Lead/pick
Power Lapper
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical areas checked:
Wear on outside diameter
Flatness
Piston holes out of round/elongated
Tools:
Light
Lapping plate
Pencil Lead/pick
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Rib
Port
Seal Bands
Thrust Face
Looking for scratches, discoloration, cavitation
Tools:
Straight Scale (check levelness of contact surfaces)
Light
Pencil Lead
Lapping Plate
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Piston Bore
Bronze Surface/Thrust Surface
Seal Bands
Tools:
Light
Pencil Lead
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Seal Band
Contact area of Port Plate
Fretting on bearing surface of Port Plate
Tools:
Light
Pencil Lead
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Trunnion
Slipper contact area
Bearing surface
Tools:
Light
Critical Areas Checked:
Gasket surface
Seal counter-bore
Mounting face
Tools:
Light
Pencil lead
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |
Critical Areas Checked:
Needle bearing surface
Splines
Roller bearing surface
Tools:
Light
Pencil lead
Micrometer for measuring splines
| Part No. or Description | Quantity Inspected | Quantity Reusable | Average Part Price | Total Value of Quantity Inspected | Total Value of Quantity Reusable |
| Totals: |