Salvage of Final Drive and Differential Thrust Washer Used in Off-Highway Trucks, Tractors, and Wheel Loaders {0677, 0760, 3258, 3284, 4050, 4055, 4201} Caterpillar

Off-Highway Truck/Tractor

773D (S/N: 7ER1-UP)

784B (S/N: 5RK1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: AP21-UP; 1HW1-UP; APX1-UP; 5AZ1-UP)

785D (S/N: DMC1-UP; MSY1-UP)

785G (S/N: SH21-UP; RTL1-UP)

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

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

789D (S/N: SP21-UP; SPD1-UP; SHH1-UP; TWP1-UP)

789G (S/N: TR21-UP)

793 (S/N: 3SJ1-UP)

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

Wheel Dozer

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

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)

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)

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 : 1V-6317 Gear Thrust Washer, and 6G-6523 Fianl Drive Thrust Washer.

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”. 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 includes the procedures for visual inspection and salvage of the 6G-6523 Final Drive Thrust Washer and the 1V-6317 Differential Thrust Washer. Several conditions can cause final drive/differential thrust washers to become worn. Wear during normal operating conditions can cause the slots to become elongated. This elongation causes undesirable circumferential movement of the washer

To correct slot wear and elongation, use the “Salvage Procedure” in this Guideline. This procedure gives step-by-step instructions for machining two new slots 90° from the original slots.

Thrust washers that meet the specifications of this Guideline can be expected to perform normally in the same application until the next overhaul. Never install a part that this Guideline indicates cannot be used again. Before installing a used or reconditioned part, correct any conditions that may have caused the original wear.

Service Advisories, Service Letters, and Technical Service Bulletins

Equipment Needed

Table 2 provides a list of machines and tooling recommended for this salvage procedure. The salvage procedure can also be completed using equivalent machinery.

Visual Inspection

Slot Wear

Illustrations 3 and 4 show different amounts of wear in the slots on the 6G-6523 Final Drive Thrust Washer. Illustration 4 shows an indentation, indicated by the arrow, caused the improper alignment of the dowel pin.

Illustration 3	g02175422
Slot wear and discoloration.

Illustration 4	g02175432

Illustrations 5 and 6 show the slot wear in the 1V-6317 Differential Thrust Washer.

Illustration 5	g02175444
Discoloration and circumferential slot wear.

Illustration 6	g02175448
Close-up of elongation of the slot.

Salvage Procedure

This salvage procedure provides instructions for machining new slots in the thrust washers.

1. Use a glass bead machine to clean the thrust washer of all debris and discoloration thoroughly.
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   Illustration 7	g02175466
   Align the slots of the thrust washer.

2. Support the thrust washer on parallel bars. Use a machinist square to align the two existing slots, as shown in Illustration 7. When slots are aligned, clamp the thrust washer in place.

3. Attach a dial indicator to the spindle, and move the table until the thrust washer is centered under the spindle. Use the dial indicator to align (zero) the ID of the thrust washer to within 0.13 mm (0.005 inch) TIR (Total Indicator Runout). See Illustrations 8 and 9.
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   Illustration 8	g02175487
   1V-6317 Differential Thrust Washer- centered.

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   Illustration 9	g02175492
   Center (zero) the 6G-6523 Final Drive Thrust Washer under the spindle.

4. Remove the dial indicator and insert the appropriate end mill cutter specified in Table 3.
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   Table 3

   End Mill and Slot Specifications
   Part No.	Cutter Size	Slot Width	Slot Depth
   6G-6523	9.53 mm (0.375 inch)	9.53 ± 0.13 mm (0.375 ± 0.005 inch)	12.20 mm (0.480 inch)
   1V-6317	6.35 mm (0.250 inch)	6.48 ± 0.13 mm (0.255 ± 0.005 inch)	12.95 mm (0.510 inch)

5. Move the table left or right to position the cutter at the side (edge) of the thrust washer. Move the table until the cutter just contacts the side of the washer. Remove stock to the depth shown in Table 3. See Illustrations 10, 11 and 12.
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   Illustration 10	g02175515
   Machine the slot to the depth specified in Table 3.

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   Illustration 11	g02175520
   6G-6523 Final Drive Thrust Washerafter machining is complete. New slots are indicated by the arrow.

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   Illustration 12	g02175647

6. Use a deburr knife to remove burrs from the machined surfaces. All machined surfaces must be free from cracks and porosity.