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)

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

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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

NOTICEKeep 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

Illustration 2 g01546400The illustration shows a clutch plate with a spiral radial pattern.

Illustration 3 g01546418



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.

Illustration 4 g01546420The illustration shows a clutch plate with a pattern of multiple parallel grooves.

Illustration 5 g01546898The 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 gThe 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.

Illustration 7 g01611491Notches are worn into the teeth of the disc.

Illustration 8 g01561336The illustration shows notches that are worn into the teeth of a friction disc.

(A) Notch

(B) Normal tooth surface

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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.

Illustration 9 g01611496The illustration shows a disc with friction material that is glazed. The disc can be used again after the disc is cleaned.

Illustration 10 g01611555The 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 gThe disc shows light erosion.

Illustration 12 gThe 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 gThe disc shows light heat checking and glazing. The disc also shows moderate erosion.

Illustration 14 gThe 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 gThe disc shows heavy erosion.




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

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





Illustration 18 gThe 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 gThe friction material on the disc has been gouged by foreign material.




Reuse the disc after reconditioning.

Illustration 20 gThe 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 gMaterial is starting to pull out around some of the cracks from heat. Discs that are similar to the disc in the illustration shobe 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 gThe 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 gThe 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


Illustration 24 g01524627The 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.

Illustration 25 g01560639The 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.

Illustration 26 g01562073(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)

Illustration 27 g01560634The 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.

Illustration 28 g01560713The clutch plate shows excessive wear. The plate can be put through the reconditioning operation if the thickness is correct.

Illustration 29 g01560715The 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.

Illustration 30 g01560974The plate shows circumferential grooves. The plate can only be reused after reconditioning.

Illustration 31 g01560979The 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

Illustration 33 g01561073The Blue and black color indicates extreme overheating. The plate should be carefully checked for warp or dish before reconditioning.

Illustration 34 g01561218Brown 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.

Illustration 35 g01561257Measure the clutch plates for a difference of thickness at area (H) and area (J) .

Illustration 36 g01560974The 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

Illustration 37 g01561443The difference in thickness for this clutch plate is within the specifications. The plate can be used again after the glaze is removed.

Illustration 38 g01561456Use 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.

Illustration 39 g01561468The clutch plate is lightly smeared. The plate must be put through the reconditioning operation if the plate will be reused in a load clutch.

Illustration 40 g01561470The 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 gThe 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.

Illustration 42 g01561466The new clutch plate shows original marks on the face of reaction.

Illustration 43 g01561463The 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

Illustration 44 g01611702The measuring of inside gap (B) is shown.

Illustration 45 g01621346Measurements 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.

Illustration 46 g01611707Measurements of outside gap (A) and inside gap (B) .

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Fri May 14 13:45:23 EST 2010



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