Guia de Reusabilidad - Power Shift PDF

Reuse And Salvage Guidelines
Transmission Clutch Plates and Disc Assemblies with Sintered Bronze Friction Material
{3030, 3155, 3190}
Articulated Truck: All
Track-Type Tractor: All
Underground Articulated Truck: All
Wheel Loader: All
Landfill Compactor:
816B (S/N: 15Z1-UP)
816F Series 2 (S/N: BZR1-UP)
816F (S/N: 5FN1-UP; BMR1-UP)
826C (S/N: 87X1-UP)
826G Series II (S/N: AYH1-UP)
826G (S/N: 7LN1-UP)
826H (S/N: AWF1-UP)
836 (S/N: 3RL1-UP; 7FR1-UP)
836G (S/N: BRL1-UP; 7MZ1-UP)
836H (S/N: BXD1-UP)
Soil Compactor:
815B (S/N: 17Z1-UP)
815F Series 2 (S/N: BYN1-UP)
815F (S/N: BKL1-UP; 1GN1-UP)
825C (S/N: 86X1-UP)
825G Series II (S/N: AXB1-UP)
825G (S/N: 6RN1-UP)
825H (S/N: AZW1-UP)
Integrated Toolcarrier:
IT28F (S/N: 1JL1-UP; 3CL1-UP)
IT28G (S/N: EWF1-UP)
IT38F (S/N: 6FN1-UP; 5DR1-UP)
IT38G Series II (S/N: JAN1-UP; CSX1-UP)
IT38G (S/N: 7BS1-UP; 1CW1-UP)
IT38H (S/N: JNJ1-UP)
IT62G Series II (S/N: AYA1-UP)
IT62G (S/N: AKP1-UP; 6PS1-UP)
Load Haul Dump:
R1600 (S/N: 9XP1-UP; 9EW1-UP)
R1600G (S/N: 9PP1-UP; 9YZ1-UP)
R1700G (S/N: 8XZ1-UP)
R2900 (S/N: 5TW1-UP)
R2900G (S/N: GLK1-UP; JLK1-UP)
Motor Grader:
Shutdown SIS

Previous Screen
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Media Number -SEBF8013-05 Publication Date -25/02/2009 Date Updated -25/02/2009

i03486280
Pgina 1de 37 Media Search - SEBF8013 - Transmission Clutch Plates and Disc Assemblies with ...
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16M (S/N: B9H1-UP)
24H (S/N: 7KK1-UP)
24M (S/N: B9K1-UP)
Transmission:
TH48-C32P (S/N: PKG1-UP)
TH48-E70 (S/N: JGC1-UP; KSH1-UP)
TH48-E80 (S/N: FRT1-UP)
TH55-E70 (S/N: PCJ1-UP)
Off-Highway Truck/Tractor:
69D (S/N: 9SS1-UP; 9XS1-UP)
768C (S/N: 02X1-UP)
769C (S/N: 01X1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770 (S/N: BZZ1-UP)
772 (S/N: RLB1-UP)
772B (S/N: 64W1-UP)
773B (S/N: 63W1-UP)
776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)
776D (S/N: 5ER1-UP; AFS1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
777F (S/N: JRP1-UP; JXP1-UP)
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
797 (S/N: 5YW1-UP)
Quarry Truck:
771C (S/N: 3BJ1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
Pipelayer:
572R Series II (S/N: DSC1-UP)
572R (S/N: AAC1-UP; 2HZ1-UP)
578 (S/N: 8HB1-UP)
583R (S/N: 2XS1-UP)
583T (S/N: CMX1-UP)
587T (S/N: FAT1-UP)
589 (S/N: 31Z1-UP)
Road Reclaimer/Soil Stabilizer:
RM-350 (S/N: 5FK1-UP)
RM-350B (S/N: AXW1-UP)
RM-500 (S/N: ASW1-UP)
RM350B (S/N: 7FS1-UP)
SM-350 (S/N: 1RM1-UP)
Track-Type Loader:
955L (S/N: 13X1-UP)
983B (S/N: 58X1-UP)
Track-Type Skidder:
517 (S/N: 5WW1-UP; 6PW1-UP)
527 (S/N: 2RS1-UP; 3DS1-UP; 4NS1-UP; BDW1-UP)
Wheel Dozer:
814B (S/N: 16Z1-UP)
814F Series 2 (S/N: BXG1-UP)
814F (S/N: BGF1-UP; 9DM1-UP)
824C (S/N: 85X1-UP)
824G Series II (S/N: AWW1-UP)
824G (S/N: 4SN1-UP)
824H (S/N: ASX1-UP)
834B (S/N: 7BR1-UP; 92Z1-UP)
834G (S/N: BPC1-UP; 6GZ1-UP)
834H (S/N: BTX1-UP)
844 (S/N: BBN1-UP; 2KZ1-UP)
844H (S/N: BTW1-UP)
854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)
854K (S/N: 2211-UP)
Wheel Tractor-Scraper:
611 (S/N: 6SZ1-UP)
615 (S/N: 46Z1-UP; 47Z1-UP)
615C Series II (S/N: 9XG1-UP)
615C (S/N: 2XG1-UP; 5TF1-UP)
651E (S/N: 89Z1-UP)
657E (S/N: 90Z1-UP; 91Z1-UP)
Introduction
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, please 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
Cancelled Part Numbers and Replaced Part Numbers
This document does not include cancelled part numbers and replaced part numbers. Use the
Numerical Parts Record (NPR) on the Service Information System (SIS) for information about
cancelled part numbers and replaced part numbers. NPR will provide the current part numbers for
replaced parts.
Summary
The installation of new components is not often necessary during transmission repair. The
installation of reconditioned components can result in large cost reductions. The document was
developed in order to provide visual guidelines for reusing assemblies of clutch disc and clutch
plates in transmissions. Also, procedures to recondition sintered bronze friction discs are given in
this guideline. The clutch discs in the guideline are made with sintered bronze material for friction
on clutch discs. Never install a part that should not be reused according to this guideline.
During the procedure for reconditioning a transmission, conditions that caused the original failure
should be corrected before putting the transmission back into operation.
There will be many "DO NOT USE AGAIN" illustrations of clutch discs and clutch plates. The
term does not indicate that the clutch plate or the friction disc is scrap. The clutch plate can be used
again after going through a reconditioning operation if the plate has none of the following
characteristics:
Incorrect thickness
Incorrect flatness
Broken
Note: Improperly reconditioning clutch plates can decrease the service life of the plates and the
discs. Badly reconditioned plates can also cause improper operation of the transmission, which will
lead to transmission failure.
Refer to Guidelines For Reusable Parts And Salvage Operations, SEBF8014, "Identification and
Applications of Transmission Clutch Plates and Specifications to machine Reaction Faces for Power
Shift Transmissions". The reuse and salvage guideline must be used with this guideline for correct
specifications and identification of clutch plates.
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
NOTICE
Keep the clutch discs for individual clutches in their original sequence
and with their respective clutch housings. The original clutch discs are
made from different material for different clutches and must not be
mixed.
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
specifically 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.
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.
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.
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.

Illustration 1 g00008666
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.
References
ReferenceGuidelines For Reusable Parts And Salvage Operations, SEBF8014, "Identification and
Applications of Transmission Clutch Plates and Specifications to machine Reaction Faces for Power
Shift Transmissions"
Glossary
Chipped - Areas of friction material are broken off of the disc assemblies.
Circumferential - Circular in shape
Discoloration - Change in color
Dished - Bent in the radial direction
Erosion - The condition that includes the deterioration or breakage of the friction material on the
land edges of friction discs
Flaking - Refer to Erosion.
Flatness - The degree of change between a surface and a single plane
Glazed - The condition that includes the development of a smooth layer on the friction material that
is similar in appearance to glass
Pattern of Grooves - The design of grooves that are cut or molded into surface of friction material
Heat Checks - Radial cracks in surface of friction material
Load Clutches - Clutches that engage last
Polished - Having a shiny surface
When replacement parts are required for this product Caterpillar
recommends using Caterpillar replacement parts or parts with
equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product
damage, personal injury or death.
Radial - Located on a line from the center to the outside of a circle
Slippage - Relative rotation of discs and plates with the applied force of the piston
Smeared - The condition that includes the removal of material from one surface to another surface
Warp - Twisted out of shape
Disc Assembly
Patterns

The illustration shows a clutch plate with a spiral radial pattern.

First Inspection
After the transmission has been disassembled, carefully 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.
The illustration shows a clutch plate with a sunburst pattern.

The illustration shows a clutch plate with a pattern of multiple parallel grooves.

The illustration shows a clutch plate with a spiral X pattern of grooves.

DO NOT USE THIS PART AGAIN.
Tooth Wear
Disc assemblies should be inspected for tooth wear. Never reuse a disc assembly that has notches in
the teeth.
In clutches that undergo relatively light loads, some wear is permitted. Disc assemblies can be used
again, if notches (wear steps) are worn into some of the teeth.

Illustration 6 g
The disc that is shown in the illustration has two marks in order to show the location of cracks.

Glazing
Normal operation of a transmission may cause a disc assembly to become glazed. The disc may also
show some discoloration. Disc assemblies that have these characteristics can be used again after the
disc assemblies are cleaned. Refer to ""Procedure for Reconditioning Discs" " for the correct method
of cleaning disc assemblies. If the disc assembly is not correctly cleaned before being reused, the
disc assembly will cause excessive slippage during the operation of the transmission.

Notches are worn into the teeth of the disc.

The illustration shows notches that are worn into the teeth of a friction disc.
(A) Notch
(B) Normal tooth surface

Pgina 10de 37 Media Search - SEBF8013 - Transmission Clutch Plates and Disc Assemblies wit...
USE THIS PART AGAIN.
Reuse the disc after reconditioning.
Erosion
Disc assemblies that show light erosion can be used again. Disc assemblies with heavy erosion must
not be used again. Erosion of the friction material on a face of reaction is normally caused by high
temperatures during operation of the transmission. Discs with excessive wear on the face must not be
reused.

The illustration shows a disc with friction material that is glazed. The disc can be used again after the disc is cleaned.

The illustration shows the disc in Illustration 9 after the disc has been cleaned.
Table 1
Wear Limits for Sintered Bronze Friction Discs that are High Energy
Part Number Disc Thickness Minimum Thickness
7T-2336 5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
1P-4110

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
3P-5955

4.95 0.08 mm (0.195 0.003 inch)

4.75 mm (0.187 inch)
4S-8724

4.95 0.08 mm (0.195 0.003 inch)

4.75 mm (0.187 inch)
6Y-1363

5.59 0.08 mm (0.220 0.003 inch)

5.39 mm (0.212 inch)
7T-5481

8.53 0.13 mm (0.336 0.005 inch)

8.33 mm (0.328 inch)
8P-5646

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
9N-4387

5.59 0.08 mm (0.220 0.003 inch)

5.39 mm (0.212 inch)
9P-4251

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
9P-4252

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
9P-4253

4.95 0.08 mm (0.195 0.003 inch)

4.75 mm (0.187 inch)
9S-9923

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
9W-4662

4.95 0.08 mm (0.195 0.003 inch)

4.75 mm (0.187 inch)
Table 2
Wear Limits for Sintered Bronze Friction Discs that are Low Energy
Part Number Disc Thickness Minimum Thickness
2S-1456

4.00 0.10 mm (0.158 0.004 inch)

3.80 mm (0.150 inch)
8M-5136

4.65 0.08 mm (0.183 0.003 inch)

4.45 mm (0.175 inch)
8M-6357

4.11 0.08 mm (0.162 0.003 inch)

3.91 mm (0.154 inch)
1S-3733

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)

1S-3736 5.56 0.08 mm (0.219 0.003 inch) 5.36 mm (0.211 inch)
3S-1188

4.95 0.08 mm (0.195 0.003 inch)

4.75 mm (0.187 inch)
3S-2671

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
3S-7981

4.65 0.08 mm (0.183 0.003 inch)

4.45 mm (0.175 inch)
5N-3342

7.11 0.13 mm (0.280 0.005 inch)

6.91 mm (0.272 inch)
5N-4756

8.53 0.13 mm (0.336 0.005 inch)

8.33 mm (0.328 inch)
5N-4834

7.11 0.13 mm (0.280 0.005 inch)

6.91 mm (0.272 inch)
5S-7830

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
8M-5070

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
8M-8550

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
8P-4736

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)
9M-2176

4.95 0.08 mm (0.195 0.003 inch)

4.75 mm (0.187 inch)
9P-4878

4.95 0.08 mm (0.195 0.003 inch)

4.75 mm (0.187 inch)
7M-1385

5.56 0.08 mm (0.219 0.003 inch)

5.36 mm (0.211 inch)


Illustration 11 g
The disc shows light erosion.

Illustration 12 g
The disc shows very light glazing and moderate erosion.
Reuse the disc after the removal of the glazing during reconditioning.
Reuse the disc after the removal of glazing and heat checks during reconditioning.

Illustration 13 g
The disc shows light heat checking and glazing. The disc also shows moderate erosion.

Illustration 14 g
The disc shows heavy erosion.
Chipped Friction Material
The spiral design of the grooves on the face makes the extreme inner lands and the extreme outer
lands narrower and weaker than the rest. Although the weaker lands are more easily damaged during
manufacturing and handling, the sufficient area on the face is available in order to permit some
damage.
Disc assemblies that are chipped on the extreme outer lands and the extreme inner lands can be used
again in any application regardless of the amount of material that is missing.
Disc assemblies with chipped material that does not exceed 20 percent of the second lands can be
reused only in the following situations:
Reverse clutches on off-highway trucks
Speed clutches that are normally used for roading a machine
Foreign material can gouge out friction material. Also, the friction material can be chipped by
foreign material. Disc assemblies can be used again if the material that is chipped or gouged out of
the lands does not exceed 15 percent of the total surface. The total surface area of all the missing
material must not exceed 15 percent if additional material is chipped off the extreme inner
lands or the extreme outer lands.
Note: If all foreign material is not removed, premature failure can occur.

Illustration 15 g
The disc shows heavy erosion.


Illustration 16 g
The disc is chipped on the first land on the outside diameter and the inside diameter.

Illustration 17 g
The disc is chipped on the first land and the second land on the outside diameter and inside diameter.

Illustration 18 g
The disc is chipped on the first land and the second land on the outside diameter.

Reuse the disc after all foreign material is removed.
Heat Checks
Disc assemblies can have fine radial lines or cracks across the face of reaction of a disc. These fine
radial lines are heat checks. Disc assemblies that show heat checks can be used again after the discs
are cleaned. Refer to ""Procedure for Reconditioning discs" " for the correct method of cleaning disc
assemblies.

Illustration 19 g
The friction material on the disc has been gouged by foreign material.

Reuse the disc after reconditioning.

Illustration 20 g
The face of reaction of the disc shows heat checks. The disc can be used again after the disc is cleaned.

Procedure for Reconditioning Discs
During normal operation, disc assemblies may become glazed, and the disc assemblies may show
discoloration. This is the result of temperature and the lubricants in the transmission.
After the selection of a disc that will be reused, the disc must be thoroughly cleaned before the disc
is installed in the transmission. Both faces of reaction of the disc assembly must be cleaned with
emery cloth. A hand sander with emery cloth that is 180 grit must be used to clean the disc assembly.
Do not use a power sander to clean the disc assembly. Use the emery cloth in a clockwise direction
or a counterclockwise direction to the diameter of the disc assembly. Do not use emery cloth in a
radial direction.
After both faces of reaction are cleaned with emery cloth, the disc assembly must be washed in
petroleum based solvent or a light caustic solution that will not harm the friction material of the disc
assembly. If the disc assemblies are not washed, foreign material can get into the lubrication system
of the transmission.

Illustration 21 g
Material is starting to pull out around some of the cracks from heat. Discs that are similar to the disc in the illustration sho
be used in load clutches in the same application. The discs can be used after reconditioning in clutches that engage first.

Clutch Plates
Nomenclature

Illustration 22 g
The illustration shows the cleaning of a friction disc with an emery cloth.

Several illustrations in this publication show plates with flat bottom slots for pins. The tangs on the
plates that have flat bottom slots are more susceptible to breakage. Do not reuse plates with flat
bottom slots. Plates in truck transmissions may be reused in the same transmission if the plates meet
all other criteria for reusability.

Illustration 23 g
The illustration shows the nomenclature for a transmission clutch plate.
(A) Face of reaction
(B) Tang
(C) Slot for pin
(D) Inside diameter
(E) Outside diameter
First Inspection
When the transmission is disassembled, carefully inspect each clutch plate. Any clutch plate that is
broken cannot be used again. Any clutch plate that has a crack should not be reused. Look for tangs
that have been broken or have a crack. Also, inspect the faces of reaction for radial cracks or deep
grooves. Carefully look for small cracks. Smaller cracks can resemble machining marks. The
following methods can be used in order to inspect the plate for cracks:
Method for using a dye penetrant
Method for using the magnetic particle

The clutch plate has a broken tang.

Wear on the Slot for the Pin
The movement of a transmission clutch plate against a pin will cause wear in the slot for the pin.
This wear must be checked before the clutch plate is installed in the transmission. Excessive wear in
the slot for the pin can cause the tang to break.
To check the slot for the pin for wear, measure the radial width of the wear marks. The maximum
permissible width of the wear marks is shown in Table 3. Check the slot for the pin for wear on the
bottom. Do not use a clutch plate that shows this type of wear.

The clutch plate has a radial crack.

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 of 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.
Excessive Wear
Do not use clutch plates that show excessive wear on a face of reaction. Excessive wear will cause
rapid wear of the disc assembly. Excessive wear can prevent correct operation of the transmission.
There is excessive wear if the original marks from grinding on the face of reaction cannot be seen. If
a clutch plate with excessive wear has the correct thickness, the plate can be put through the
reconditioning operation. If a clutch plate shows the start of wear, but the original marks from
grinding can be seen, the plate can be used again.
(F) Maximum width of the slot
(G) Maximum width of the radial indentation
Table 3
Wear Limits for the Slot for the Pin
Diameter of the
Reaction Pin
Maximum Width of the
Slot (F)
Maximum Width of the Radial
Indentation (G)

12.70 mm (0.500 inch)

16.26 mm (0.640 inch)

9.7 mm (0.38 inch)

15.9 mm (0.63 inch)

19.43 mm (0.765 inch)

9.7 mm (0.38 inch)

The clutch plate shows wear in the bottom of the slot for the pin.

Circumferential Grooves
Circumferential grooves on clutch plates can be an indication of foreign material in transmission oil
systems.
Do not use clutch plates that show circumferential grooves. Clutch plates with circumferential
grooves will cause rapid wear of the disc assembly that comes in contact with the grooves. These
clutch plates can be used again only if the plates are reconditioned.

The clutch plate shows excessive wear. The plate can be put through the reconditioning operation if the thickness is
correct.

The clutch plate shows the start of wear. The original marks from grinding can be seen.

The inspection of some clutch plates will show the beginning of circumferential marks, but no
grooves. These plates can be used again. The plate must be installed in the transmission so the face
of reaction is in the same disc assembly. Also, the face of reaction must be in contact with the same
disc assembly. If these plates are not in contact with the original disc assembly, the plates must be
put through the reconditioning operation before the plates can be used again.
Note: Clutch plates with circumferential marks that are not grooves can only be used in clutches that
engage first. Do not use these plates in load clutches. Refer to Guidelines For Reusable Parts And
Salvage Operations, SEBF8014, "Identification and Applications of Transmission Clutch Plates and
Specifications to machine Reaction Faces for Power Shift Transmissions" for the correct location of
the load clutches.

The plate shows circumferential grooves. The plate can only be reused after reconditioning.

The plate shows circumferential grooves. The plate can only be reused after reconditioning.

Reuse this part in clutches that engage first only.
Discoloration
When the transmission is engaged, a small amount of slippage gives the transmission smooth
operation. When the slippage becomes excessive, friction causes more heat in the clutch plates and
disc assemblies. The heat will discolor the clutch plates, and the heat will damage the faces of
reaction. Heat can also cause the plates and/or discs to warp. If the plates that show discoloration are
not warped or the plates are not Dished the plates can be reused. Do not use clutch plates that show
heat checks. Plates that have heat checks cannot be put through the reconditioning operation.

Illustration 32 g

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 tangs will have little sign of wear

The Blue and black color indicates extreme overheating. The plate should be carefully checked for warp or dish before
reconditioning.

Brown or blue discoloration indicates less extreme overheating. The clutch plate can be used again after reconditioning.
on the face of reaction between the tangs. Specifications for thickness differences for each clutch
plate are given in Guidelines For Reusable Parts And Salvage Operations, SEBF8014, "Identification
and Applications of Transmission Clutch Plates and Specifications to machine Reaction Faces for
Power Shift Transmissions".
Use a micrometer in order to measure the thickness differences. 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 one measurement from the other measurement. This will be the difference in thickness.
Measure the thickness of the disc at each high spot on the clutch plate. If the difference in thickness
at any point on the clutch plate is more than the given specification, the clutch plate cannot be used
again. Excessive slippage will occur if the plate is used again in the current state. These clutch plates
can be put through a reconditioning operation.
Clutch plates that show high spots at the tangs, which are within the specifications for thickness
difference can be used again after the glaze is removed.

Measure the clutch plates for a difference of thickness at area (H) and area (J ) .

The thickness difference for this clutch plate is more than the given specification.

Reuse the plate after the removal of glazing.
Procedure for Reconditioning Plates
Use a hand sander with paper that is 80 grit that is wet or dry in order to remove the glaze. Also, use
the paper for the replacement of some of the marks from grinding to area of the high spot. The
abrasive material should be used in a radial direction only. Clean the surface thoroughly with a brush
and solvent after the glaze is removed.
Note: Never use the abrasive material in a circumferential direction on a clutch plate with a high
spot.
The reconditioned surface must be rough enough to wear the corner of a copper coin. The new
surface of a clutch plate is rough enough to wear the corner of a copper coin. Do not use a power
sander or an abrasive pad for cleaning to remove glaze from a plate.
Smeared Faces of Reaction

The difference in thickness for this clutch plate is within the specifications. The plate can be used again after the glaze is
removed.

Use emery cloth that is 80 grit that is wetted with solvent to remove glaze from a high spot. Use the cloth in the
direction in the illustration.
Clutch plates will show light smeared faces of reaction and heavy smeared faces of reaction.
Smeared clutch plates have bronze lines on the faces of reaction. The lines are bronze material that is
transferred from the friction material to the disc assemblies.
Clutch plates that have narrow circumferential lines are known as lightly smeared plates. Clutch
plates that are lightly smeared can only be reused in clutches that engage first. Do not use these
plates in load clutches. Refer to Guidelines For Reusable Parts And Salvage Operations, SEBF8014,
"Identification and Applications of Transmission Clutch Plates and Specifications to machine
Reaction Faces for Power Shift Transmissions" for the correct location of load clutches.
Note: Do not reuse clutch plates that are heavily smeared. Heavily smeared plates can only be reused
after reconditioning.
Reuse the plate in clutches that engage first only.

The clutch plate is lightly smeared. The plate must be put through the reconditioning operation if the plate will be
reused in a load clutch.

The clutch plate is lightly smeared. The plate must be put through the reconditioning operation if the plate will be
reused in a load clutch.

Reuse the plate after reconditioning.
Polished Faces of Reaction
The normal operation of a transmission will cause the clutch plates and disc assemblies to wear. The
top photo shows a new clutch plate. When the plate was machined, marks were put on the face of
reaction. Throughout normal operation, the marks will wear away.
Do not use clutch plates that have a smooth, polished face of reaction. Some clutch plates will have a
face of reaction that is smooth and polished, and the original marks can still be seen. Illustration 42
shows the original marks. Other clutch plates will have a smooth, polished face of reaction and the
original marks will be worn off. Clutch plates that have a polished face of reaction can be used again
after reconditioning, if the clutch plates are within the specifications for the reconditioning operation.

Illustration 41 g
The clutch plate is heavily smeared. The plate can be used again after reconditioning.

Reuse the plate after reconditioning.
Procedure for Checking Flatness
Transmission clutch plates and disc assemblies must be flat within the following limits in order to be
reused. The plates and discs must be checked for both warp and dish. The plates may be warped, or
the plates may be dished so the plates should be checked for both forms of wear. Any plate or any
disc that has more than 0.38 mm (0.015 inch) of warp must not be used again. Any plate or any disc
that is dished to more than 0.13 mm (0.005 inch) must not be used again. At the same time, plates
and discs may be warped and plates and discs may be dished. These plates or discs can be used again
if the difference between the measurement for the area that is dished and the measurement for the
area that is warped is not more than 0.15 mm (0.006 inch). Use the following procedure to check
either a clutch plate or disc assembly for flatness.

The new clutch plate shows original marks on the face of reaction.

The clutch plate shows a polished face of reaction. The plate can be used again after reconditioning.

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 surface plate. If dished area is obvious, put the plate on the

The measuring of inside gap (B) is shown.

Measurements of outside gap (A) and inside gap (B) .
(C) outside diameter
(D) inside diameter
flat surface so the concave side is up.
3. Measure inside gap (B) between the plate or the disc and the surface of inspection with a
thickness gauge. The plate or the disc cannot be reused if the gap is more than 0.38 mm (0.015
inch) at any point around the circumference of the plate.
Check for Dished Plates and Discs
1. Measure the gap between the plate or the disc and the surface for inspection with a thickness
gauge at the outside edge of the plate or disc.
2. If outside gap (A) at any point is 0.15 mm (0.006 inch) larger or smaller than inside gap (B),
then the plate or the disc can not be used again.

Measurements of outside gap (A) and inside gap (B) .
Copyright 1993 - 2010 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri May 14 13:45:23 EST 2010

Guia de Reusabilidad - Power Shift PDF

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Reuse And Salvage Guidelines

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