Transmission Clutch Plates and Disc Assemblies with Cellulose Friction Material {3030, 3155, 3190} Caterpillar

Agricultural Tractor

65 (S/N: 7YC1-UP)

65B (S/N: 7YC1-UP)

65C (S/N: 2ZJ1-UP)

65D (S/N: 2ZJ1-UP)

65E (S/N: 1GM1-UP; 6GS1-UP)

70C (S/N: 2YL1-UP)

75 (S/N: 4CJ1-UP)

75C (S/N: 4KK1-UP)

75D (S/N: 5AR1-UP)

75E (S/N: 1HM1-UP; 6HS1-UP)

85C (S/N: 9TK1-UP)

85D (S/N: 4GR1-UP)

85E (S/N: 1NM1-UP; 6JS1-UP)

95E (S/N: 1SM1-UP; 6KS1-UP)

Articulated Truck

725 (S/N: WWA1-UP; B1L1-UP; AFX1-UP)

725C (S/N: TFB1-UP)

725C2 (S/N: 2T31-UP)

730 (S/N: WWB1-UP; AGF1-UP; B1M1-UP)

730C2 (S/N: 2T41-UP)

735 (S/N: B1N1-UP; AWR1-UP)

735C (S/N: LFJ1-UP; TFJ1-UP)

740 EJECTOR (S/N: 3F71-UP; 3T71-UP)

740C EJECTOR (S/N: LFN1-UP; TFN1-UP)

745 (S/N: 3F61-UP; 3T61-UP)

745C (S/N: LFK1-UP; TFK1-UP)

D20D (S/N: 9MG1-UP)

D250B (S/N: 5WD1-UP)

D250D (S/N: 6NG1-UP)

D250E (S/N: 5TN1-UP)

D250E Series II (S/N: 4PS1-UP)

D25C (S/N: 9YC1-UP)

D25D (S/N: 1HK1-UP)

D300B (S/N: 4SD1-UP)

D300D (S/N: 5MG1-UP)

D300E (S/N: 7FN1-UP)

D300E Series II (S/N: 5KS1-UP)

D30C (S/N: 7ZC1-UP)

D30D (S/N: 3AJ1-UP)

D350C (S/N: 8XC1-UP)

D350D (S/N: 9RF1-UP)

D35C (S/N: 2GD1-UP)

Backhoe Loader

All

Earthmoving Compactor

All

Engine

7211 (S/N: 1YB1-UP)

7221 (S/N: 1ZB1-UP)

Integrated Toolcarrier

All

Landfill Compactor

All

Load Haul Dump

R1300 (S/N: 6QW1-UP)

R1300G (S/N: LJB1-UP)

R1300G Series II (S/N: RSL1-UP)

R2900G (S/N: NLK1-UP)

R3000H (S/N: RCY1-UP)

Motor Grader

All

Off-Highway Truck/Tractor

777G (S/N: T4Y1-UP)

On-Highway Transmission

All

Petroleum Transmission

All

Pipelayer

All

Soil Compactor

All

Track-Type Loader

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

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

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

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

933 (S/N: 8FL1-UP; 9EL1-UP)

935B (S/N: 3DF1-UP)

935C (S/N: 8CF1-UP)

935C Series II (S/N: 5DJ1-UP)

939 (S/N: 9GL1-UP)

941 (S/N: 70H1-UP; 80H1-UP; 16U1-UP)

941B (S/N: 70H1-UP; 80H1-UP)

951 (S/N: 79H1-UP; 86J1-UP)

951B (S/N: 79H1-UP; 86J1-UP)

951C (S/N: 86J1-UP)

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

955K (S/N: 61H1-UP; 85J1-UP)

955L (S/N: 64J1-UP; 85J1-UP; 13X1-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 Skidder

All

Track-Type Tractor

All

Transmission

All OEM Transmissions

Truck Engines

7155 (S/N: 56K1-UP; 72S1-UP)

Wheel Dozer

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

814F (S/N: BGF1-UP; 9DM1-UP)

814F Series 2 (S/N: BXG1-UP)

824G Series II (S/N: AWW1-UP)

824H (S/N: ASX1-UP)

834B (S/N: 7BR1-UP; 92Z1-UP)

834H (S/N: BTX1-UP)

834S (S/N: 96G1-UP)

834U (S/N: 14B1-UP)

844H (S/N: BTW1-UP)

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

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

Wheel Loader

All

Wheel Skidder

All

Wheel Tractor-Scraper

611 (S/N: 6SZ1-UP; 7WZ1-UP)

613 (S/N: 71M1-UP; 72M1-UP)

613B (S/N: 72M1-UP; 38W1-UP)

613C (S/N: 92X1-UP; 93X1-UP)

613C Series II (S/N: KEH1-UP; 8LJ1-UP; TJK1-UP; LCZ1-UP)

613G (S/N: ESB1-UP; DBE1-UP)

615 (S/N: 46Z1-UP; 47Z1-UP)

615C (S/N: 5TF1-UP; 2XG1-UP)

615C Series II (S/N: 9XG1-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 reusability inspection of cellulose friction discs in power shift transmissions.

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

It is not always necessary to install new components when you recondition a transmission. The installation of used components can result in large reductions in repair costs. This guideline gives visual criteria to reuse clutch discs with cellulose friction material and the clutch plates that mate to the clutch discs.

Never install a part that should not be used again according to the specifications in this document. Some types of cellulose friction material will wear grooves in surfaces in contact with the cellulose friction material. The friction material will only have a small amount of wear. The discs can be used again without reconditioning if none of the following damage exists:

• Scratches

• Discoloration

• Warp

• Dish

Note: Be sure that the correct type of oil is used in the transmission. The additives that are in some oils attack the material for friction on the discs. The additives may result in greatly reduced operating life.

Procedures to recondition scratched surfaces or lightly pitted faces of reaction are given in this guideline. Also, specifications for the maximum amount of warp and dish are given. Do not use any other method of cleaning or reconditioning. Do not use any of the following methods:

• Machining with a lathe

• Clean with grit or glass beads

• Clean with abrasive pads for reconditioning

Any method that changes the surface finish of the face of reaction can cause rapid wear of the friction material. Correct any conditions that caused the original failure during reconditioning.

Note: Transmission discs are made with friction material. Cellulose friction material is used for discs. RAYFLEX friction material is used for discs. Cellulose discs are similar in appearance to RAYFLEX discs. Cellulose discs and RAYFLEX discs have different criteria for reusability. This guideline gives reusability information for cellulose discs only.

References

Service Advisories, Service Letters, and Technical Service Bulletins

Tooling and Equipment

Note: The Tooling and Equipment in Table 3is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

Glossary

Chipped - Areas of friction material are broken off the disc assemblies.

Discoloration - Change in color

Dished - Bent in the radial direction

Erosion - The condition that includes deterioration or breakage of the friction material on the land edges of friction discs

Glazed - The condition that includes the development of a smooth layer on the friction material that is similar in appearance to glass

Mating - Parts that operate together through contact

Nick - Small notch

Warp - Twisted out of shape

Disc Assembly

Identification

This document is only to be used for the intended specific components. This document applies to discs in planetary sets for power shift transmissions. Caterpillar uses several different types of friction material on clutch plates. As a rule, assume that each type of friction material requires a different surface finish for the face of reaction. Each type of friction material has different wear characteristics and failure modes.

The following section identifies the features of clutch discs with cellulose friction material.

Illustration 3	g03783569
The illustration shows a pattern for cellulose friction material.

Illustration 4	g03783574
The pattern of parallel grooves is used for cellulose friction material.

Illustration 5	g03783576

Illustration 6	g03783577
The pattern of parallel grooves is pressed or embossed and not cut.

Illustration 7	g06265280
The illustration shows a pattern for cellulose friction material.

The cellulose friction material that is used on transmission discs is dark gray or nearly black. Cellulose friction material is similar in appearance to RAYFLEX friction material. Illustrations 3, 4, and 7 show patterns of grooves. Cellulose discs use only these patterns of grooves. These patterns were not used for RAYFLEX or F37 friction material.

Cleaning Friction Material

Chlorinated solvents, diesel fuel, kerosene, and petroleum distillates can be used to clean discs with cellulose friction material. Petroleum distillates include Stoddard solvent and naphtha. Cellulose friction material is porous. Incorrect materials for cleaning or processes can damage cellulose material. Incorrect materials for cleaning or processes can cause a premature failure.

Follow the following precautions:

1. Do not use solvents that have a higher temperature than 38 °C (100 °F).

2. Minimize the time of contact between solvents and discs.

3. Use towels or compressed air to dry the discs after washing.

4. To avoid chipping of friction material, do not stack discs after the cleaning.

DO NOT USE any of the following types of cleaning materials. DO NOT PERMIT the following materials for cleaning to come in contact with the cellulose friction material. These materials will weaken the base material. These materials will cause the base material to break up in operation.

• Water or steam

• Water-based cleaning solutions such as 486-1526 Degreaser and 486-1524 Cleaner.

• Freon

• Thinner for paint

• Ketones, aldehydes such as MEK and acetone

Visual Inspection

Cracks and Grooves

After the transmission has been disassembled, carefully clean, dry, and inspect each disc assembly. Any disc assembly that has a crack or deep grooves cannot be used again. Look for teeth that have been broken or cracked. Inspect the friction surfaces for radial cracks or deep grooves.

Illustration 8	g03784023
The illustration shows a friction disc with cracks. DO NOT USE THIS PART AGAIN

Handling Damage

Some damage to transmission discs may occur due to rough handling (contact with hard, sharp objects). The discs may be reused if the discs meet the following criteria:

• Discs are not easily damaged during normal handling.

• A maximum of six damaged areas are permitted per face.

• The area of handling damage on any face is 100 mm² (0.16 inch²) or less.

Illustration 9	g03784027
This disc has excessive damage from handling. The maximum allowed area of damage from handling on any face is 100.0 mm2 (0.16 inch2). The area of damage on the disc in Illustration 9 is 123.0 mm2 (0.16 inch2). DO NOT USE THIS PART AGAIN

Erosion

Illustration 10	g03784032
Light erosion on the edges of the lands is shown on the disc. OK TO USE THIS PART AGAIN

Illustration 11	g03784038
Excessive erosion is shown on the face of the disc. DO NOT USE THIS PART AGAIN

Damage from Water

Exposure of the transmission discs to water and antifreeze as a result of cooler failure in the core, vandalism, accidentally immersing the machine, and so on. Exposure to water or antifreeze will result in shortened service life. Since the length of contact can often be extensive, replace the discs.

Bond Failure

Overheating of the friction surfaces, exposure to contaminated lube oil, or other incompatible materials can weaken the bond between the friction material and the steel core. The bond may be weak if material is chipped off the core during normal handling.

Illustration 12	g03784043
The friction material was chipped cleanly from the core of the disc on top. The friction material was not chipped cleanly on the top disc. DO NOT USE THIS PART AGAIN

This part is not to be used again due to the weak bond.

Glazing

Excessive clutch slippage generates heat. Heat can cause surfaces on the discs to become glazed. The glazing causes a reduced coefficient of friction. The reduced coefficient of friction causes more slippage and finally complete clutch failure. Glazing can be identified by a shiny appearance of the friction material. Glazing can cover the entire surface or glazing may be in the bands. The normal surface has a porous appearance. NO GLAZING IS PERMITTED.

Illustration 13	g03784047
Glazing of the surface is shown in the illustration. DO NOT USE THIS PART AGAIN

Do not use this part again due to glazing of the surface.

Tooth Wear

Disc assemblies should be inspected for tooth wear. Some tooth wear is acceptable. If notches are worn into the teeth, the disc should never be used.

Illustration 14	g03784052
The illustration shows notches that are worn into the teeth. DO NOT USE THIS PART AGAIN (1) A notch is worn into a tooth. (2) Normal Tooth Surface

Illustration 15	g03784056
The illustration shows shallow wear but no obvious wear step. OK TO USE THIS PART AGAIN (3) Shallow wear but no obvious wear step (4) Normal Tooth Surface

Measurement of Face Wear and Disc Thickness

Excessively worn faces on discs can cause two types of problems:

• Insufficient stack height

• The restriction of the flow of oil for cooling because of the reduction of the oil groove depth.

Use a micrometer to measure the thickness at several places around the inner edges of the disc and the outer edges of the disc. If a disc that is below the minimum thickness that is shown in Table 4 DO NOT USE THIS PART AGAIN.

Note: Both sides of the disc should have the same amount of wear. If the faces are not worn equal amounts DO NOT USE THIS PART AGAIN.

Clutch Plates

Nomenclature

Illustration 16	g03784070
Nomenclature for a transmission clutch plate (5) Face of Reaction (6) Tang (7) Slot for Pin (8) Part Number (9) Inside Diameter (10) Outside Diameter

Cracked Clutch Plates or Broken Clutch Plates

Illustration 17	g03784073
The illustration shows a clutch plate with a broken tang. DO NOT USE THIS PART AGAIN

Illustration 18	g03784077
The illustration shows a clutch plate with a radial crack. DO NOT USE THIS PART AGAIN

Wear on the Slot for the Pin

Illustration 19	g03784078
(A) Maximum width of the slot (B) Maximum width of the radial indentation

Note: A plate that is worn may be reused under certain circumstances. The wear on the slot must only be on one side of the plate. The plate must meet all the limitations. The limitation on the radial indentation does not need to be met. The plate must be used in the same clutch and in the same application.

Scratches and Nicks

Remove any sharp edges that have been caused by scratches or nicks by carefully rubbing only the area of the sharp edge with a 6V-2010 Polishing Stone or with 00 emery paper and a solvent. Rub the edge until the sharp edge cannot be felt with a fingernail or a lead pencil. Put oil on the plate or on the surface to prevent rust.

Note: Use only the procedure that is shown in "Scratches and Nicks". Any other method can cause rapid wear of the disc assemblies.

Illustration 20	g03784084
The illustration shows the use of a 6V-2010 Polishing Stone for the removal of a sharp edge that was caused by a scratch or a nick. USE THIS PART AGAIN

This part can be used again after removing the sharp edge that was caused by a scratch or a nick.

Wear and Grooves

Clutch plates with polished surfaces can be reused without further preparation. Do not reuse a plate if grooves are worn into the surface of the plate. If the clutch plates have been worn evenly, and the clutch plates do not have any grooves, the clutch plates can be reused without further preparation. The minimum thickness is given in Reuse and Salvage Guideline, SEBF8014, "Identification and Applications of Transmission Clutch Plates and Specifications to Machine Reaction Faces for Power Shift Transmissions".

Illustration 21	g03784086
This plate has polished surfaces but the plate is not grooved or excessively worn. USE THIS PART AGAIN

Parts with polished surfaces can be used again if the polished surfaces are not grooved or excessively worn.

Illustration 22	g03784119
This plate has grooves and ridges in the contact surface. DO NOT USE THIS PART AGAIN

This part cannot be reused because of grooves and ridges in the contact surface.

Low Spots

The methods that are used to manufacture some plates can produce low areas near the tangs. These areas are called low spots. These low spots are thinner than the rest of the disc. Plates with low spots are reusable if the plates meet the other criteria for reusability.

Illustration 23	g03784121
Plate with low spots USE THIS PART AGAIN

Low spots are acceptable.

High Spots

Transmission clutch plates that show a high spot (shiny surface) and/or a smeared surface in the area of the tang must be checked for a difference of thickness before the plates can be used again. Normally, clutch plates that have an indication of high spots at the tang will have little sign of wear on the face of reaction between the tangs. Specifications for the thickness of each clutch plate are given in the tables for identification in Reuse and Salvage Guideline, SEBF8014, "Identification and Applications of Transmission Clutch Plates and Specifications to Machine Reaction Faces for Power Shift Transmissions".

Use a micrometer to measure differences in thickness of the plate. Measure the thickness of the face of reaction at a high spot. Also, measure the thickness of the face of reaction halfway between the high spot and the next tang.

Subtract the high measurement from the low measurement. The calculation will be the difference in thickness. Measure the difference in thickness at each high spot on the clutch plate. The clutch plate cannot be used again if the thickness difference at any point on the clutch plate is more than the given specification. These clutch plates can be put through a reconditioning operation.

Illustration 24	g03784123
Measure the clutch plates for a difference of thickness at areas (11) and (12).

Manufacturing and Handling Damage

Plates with manufacturing or handling damage can be used if all sharp edges and raised edges are removed.

Illustration 25	g03784124
Manufacturing or handling damage is shown on a clutch plate. USE THIS PART AGAIN

The part should be checked before the part is reused. The part may not have any edges that are raised or sharp edges.

Measurement Of Warp and Dish

Illustration 26	g03784127
Measurements of outside gap (C) and inside gap (D)

Illustration 27	g03784128
Measurement of outside gap (C) and inside gap (D) ( C) Outside gap (D) Inside gap (E) Outside diameter (F) Inside diameter

1. Remove any rough edges in the area of the slot for the pin.

2. Put the clutch plate on a flat surface such as a face of reaction on the housing for a clutch, a center plate for a transmission, or a Precision Flatness Plate. If dishing is obvious, put the plate on the flat surface so the concave side is up.

3. Use a 8H-8581 Feeler Gauge to measure the gap between the clutch plate and the surface for inspection at both outside diameter (E) and inside diameter (F). Measure the gap at a minimum of three points around the plate with equal distances between the points.

4. If outside gap (C) at the outside diameter at any of the points is more than 0.38 mm (0.015 inch), the clutch plate cannot be used again.

5. If inside gap (D) at the inside diameter at any of the points is more than 0.15 mm (0.006 inch), the clutch plate cannot be used again.

6. Subtract the measurement of inside gap (D) from the measurement of outside gap (C) if the gaps that were measured in Step 4 and Step 6 are acceptable. If the difference is more than 0.15 mm (0.006 inch), the clutch plate cannot be used again.

Example

The measurement of gap (C) is 0.28 mm (0.011 inch) which is less than the maximum. The measurement of gap (D) is 0.10 mm (0.004 inch) which is less than the maximum. This difference between the measurement of outside gap (C) and inside gap (D) is 0.18 mm (0.007 inch) which is more than the maximum. This clutch plate cannot be used again.