Salvage Case Assembly and Idler Shaft in Transmission Transfer Gear Groups for 621B, 623B, 627, 627B, 641, 641B, 650B, 651B, 651E, 657, 657B, 657E, 657G, 660B, 666, and 666B Tractor-Scrapers{3030, 3159} Caterpillar

Wheel Tractor-Scraper:

621B (S/N: 6XB1-UP; 7KC1-UP; 8HC1-UP; 9AC1-UP; 45P1-UP; 31V1-UP; 35V1-UP; 36V1-UP; 73V1-UP)

623B (S/N: 61E1-UP; 46P1-UP)

627 SCRP PS (S/N: 50K1-UP)

627 (S/N: 54K1-UP; 68M1-UP; 69M1-UP)

627B (S/N: 14S1-UP; 15S1-UP; 32V1-UP; 33V1-UP; 34V1-UP; 37V1-UP; 38V1-UP; 56V1-UP)

641 (S/N: 64F1-UP; 41M1-UP; 42M1-UP; 43M1-UP)

641B (S/N: 65K1-UP)

650B PS TRCTR (S/N: 58K1-UP)

651B (S/N: 67K1-UP; 45M1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP; 88Z1-UP; 89Z1-UP)

657 (S/N: 19G1-UP; 31G1-UP; 53K1-UP; 46M1-UP)

657B (S/N: 53K1-UP; 68K1-UP)

657B SCRP PS (S/N: 47M1-UP)

657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP; A4G1-UP; GER1-UP)

660B PS TRCTR (S/N: 58K1-UP)

666 (S/N: 20G1-UP; 64H1-UP)

666B (S/N: 20G1-UP; 66K1-UP)

Introduction

© 2011 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

This Reuse and Salvage Guideline provides the specifications and the procedure to recondition the idler shaft in the transmission transfer gear group for the listed models. The damage to the case assembly will determine reusability.

The idler shaft can be used again if the idler shaft meets the guidelines for reusing the idler shaft in this Reuse and Salvage Guideline or if the idler shaft is reconditioned according to these guidelines. If the idler shaft is reused, the idler shaft can be expected to give normal performance until the next overhaul when the idler shaft is used again in the same application.

Important Safety Information

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 in order 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, you must ensure that it is safe for you and for other people to use. You should 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". The "WARNING" Safety Alert Symbol is shown below.

Illustration 1	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. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must 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.

Idler Shaft and Case Assembly Damage

The idler shafts and case assemblies that are used in the power shift transmissions for the tractor scrapers listed above can be damaged if there is any rotation of the inner race of the idler gear bearing. See Illustration 2 for the location.

Illustration 2	g01239773
Transfer gear for the power shift transmission. (1) Idler shaft (2) Idler gear bearings (3) Case assembly

Idler Shaft Inspection

Inspect Face (A) of the idler shaft. See Illustration 3. If there are any grooves or any wear in Face (A), the shaft cannot be used again unless Face (A) is machined and a fabricated spacer is installed between Face (A) and the bearing.

Illustration 3	g01239854
Typical example of an idler shaft. See Table 2 for dimension references.

Idler Shaft Salvage

1. Face (B) of the Idler Shaft must be machined to Dimension (L). See Table 2 for part numbers and specifications. Use 9P-1389 Shim Pack for 9P-1388 Idler Shaft and 2P-9250 Shim Pack for 6T-2412 Idler Shaft during reassembly of the transfer gear.

2. If Face (A) is worn or grooved, machine Face (A) to Dimension (LS) as Table 2 and Illustration 4 show. Fabricate a spacer and install the spacer. See Table 3 and Illustration 6.

3. Metal spray is an acceptable method of restoring shafts with wear on Diameter (E) to the original size. See Table 2 and Illustration 3. Each step of the spraying procedure is critical to proper bonding and the surface finish. For metal spray salvage procedures, refer to Special Instruction, SERF8799, "Thermal Spray General Information Guide".

Illustration 4	g01239920
Idler shaft (AA) Maximum undercut 0.5 mm (0.02 inch) radius

Case Assembly

Inspect Face (C) of the case assembly. See Illustration 5. If there are any grooves or wear in Face (C), the case assembly cannot be used again unless Face (C) is machined and a machined spacer is installed between Face (C) and the bearing. Use the procedure that follows.

Illustration 5	g01239968
(3) Case assembly (X) Depth is machined in order to allow use of spacer. (F) Pilot diameter (G) Diameter is machined in order to allow use of spacer.

1. Inspect pilot diameter (F) of the case assembly. If the diameter has increased beyond the specifications that are shown in Table 3, the case assembly cannot be used again unless the bore is restored to the original dimensions by use of metal spray or a sleeve.

2. Machine Face (C) of the case assembly to Depth (X) and Diameter (G) as Table 3 and Illustration 5 show. The grooves or other damage in the machined area must be removed. Face (C) must be perpendicular to the bore centerline within 0.05 mm (0.002 inch).

3. Make a steel spacer as Illustration 6 shows. Dimensions are given in Table 3. The thickness (H) of the spacer is 3.18 ± 0.05 mm (0.125 ± 0.002 inch). The sides of the spacer must be parallel to each other within 0.05 mm (0.002 inch). Face (J) must have a surface finish of 0.15 µm (6 micro inch). Face (K) must have a surface finish of 6.0 µm (240 µin).

Illustration 6	g01240277
Use SAE 1020 Steel in order to machine a spacer. (H) Thickness

Assemble the shaft in the case with the bearings, gear, and the steel spacer. With your fingers, tighten the bolts which hold the shaft to the case. Measure the gap between the shaft flange and the case. Use shims from the respective shim pack (Table 3) to achieve a shim thickness of 0.51 ± 0.05 mm (0.020 ± 0.002 inch) less than the gap measurement. Remove the shaft and the case. Tighten the bolts.