RECONDITIONING PROCEDURES

CLUTCH PlATES A 0 DISC ASSEMBLIES

CHECK FOR WARP AND DISH

1. Some plates or discs will have both warp and dish.

Measure for warp and dish at a minimum of three points around the plate or disc 12.00 apart.

2. Measure the clearance between the plate or disc and the inspection surface at both outside and inside edges. 3. Subtract one measurement (clearance at outside edge or clearance at inside edge) from the other.

If the difference at any point measured, is more than .005 in. (0.13 mm), the clutch plate or disc assembly can not be used again. Example: Measurement at inside diameter is .004 in. (0.10 mm)and measurement at outside diameter is .010 in. (0.25 mm). The differ,ence is .006 'in. (0.15 mm). This- clutch plate or disc assembly can not be used again.

MEASURE FOR WARP AND DISH.

MAX.IMUM DIFFERENCE BETWEEN TWO MEASURE· MENTS (C) AND (D) A CLUTCH PLATE OR DISC ASSEMBLY CAN HAVE TO BE USED AGAIN IS .005 in. (0.13 mm).

[B CATERPILLAR

Caterpillar, Cal and 'tB are Trademarks of Caterpillar Tractor Co.

SEBF8013

PRINTED IN U.S.A. (12/75) CATERPILLAR FUNDAMENTAL ENGLISH

RECONDITIONING PROCEDURES

CLUTCH PLATES AND DISC ASSEMBLIES

FLATNESS CHECK PROCEDURE

Transmission clutch plates and disc assemblies must be flat within the following guides to be used again. When the plates or discs are checked for flatness, they must be checked for both warp and dish. Any plate or disc that has more than .015 in. (0.38 mm) of warp must not be used again. Any plate ordisc that has more than .00Sin. (0.13

mm) of dish must not be used agai n. Some plates or discs can have both warp and dish. These plates or discs can be used again if the difference between the measurement for warp and the measurement for dish is not more than .005 in. (0.13 mm). Use the following procedure to check either a clutch plate or disc assembly for flatness.

MEASURE FOR WARP

CHECK FOR WARP

1.0. -t o.D"j_A

~~:;ss3

MAXIMUM WARP (A) A CLUTCH PLATE OR DISC ASSEMBL Y CAN HAVE TO BE USED AGAIN IS .015 in. (0.38 mm).

26

1. Put the plate or disc on a flat surface, like a clutch housing reaction surface, transmission center plate or a surface plate.

NOTE: Remove any rough edges in the area of the reaction pin slot on a clutch plate before flatness is checked.

2. Measure the gap between the plate or disc and the inspection surface with a thickness gauge around the circumference of the plate or disc. If the gap, at any point around the circumference is more than .015 in. (0.38 mm), the plate or disc can not be used again.

=L'-CONDITfO ING PROCEDURES

CLUTCH PLATES AND DISC ASSEMBLIES

CHECK FOR DISH

1. Measure the gap between the plate or disc and the inspection surface with a thickness gauge at the inside edge of the plate or disc.

2. If the gap, at any point is more than .005 in. (0.13 mm), the plate or disc can not be used again.

MEASURE FOR DISH.

B

MAXIMU DIS ) A CLUTCH PLATE OR DISC ASSEMBLY

CAN HAVE TO BE USED AGAIN IS .005 in. (0.13 mm).

27

RECONDiTiONING. PROCEDURES

CLUTCH PLATES AND DISC ASSEMBLIES

FLATNESS CHECK PROCEDURE

Transmission clutch plates and disc assemblies must be flat within the following guides to be used again. When the plates or discs are checked for flatness, they must be checked for both warp and dish. Any plate or disc that has more than .015 in. (0.38 mm) of warp must not be used again. Any plate or disc that has more than .005 in. (0.13

mm) of dish must not be used again. Some plates or discs can have both warp and dish. These plates or discs can be used again if the difference between the measurement for warp and the measurement for dish is not more than .005 in. (0.13 mm). Use the following procedure to check either a clutch plate or disc assembly for flatness.

MEASURE FOR WARP

CHECK FOR WARP

)

1.0. -t o.D.-:f_tA

L~SSS\1

MAXIMUM WARP (A) A CLUTCH PLATE OR DISC ASSEMBLY CAN HAVE TO BE USED AGAIN IS .015 in. (0.38 mm).

26

1. Put the plate or disc on a flat surface, like a clutch housing reaction surface, transmission center plate or a surface plate.

NOTE: Remove any rough edges in he area of the reaction pin slot on a clutch plate before flatness is checked.

2. Measure the gap between the plate or disc and the inspection surface with a thickness gauge around the circumference of the plate or disc. If the gap, at any point around the circumference is more than .015 in. (0.38 mm), the plate or disc can not be used again.

RECONDITIONING PROCEDURES

DISC ASSEMBLIES

DISC RECONDITIONING PROCEDURE

During normal operation disc assemblies will become glazed and show discoloration, This is the result of temperature and transmission lubricants.

After the selection of any disc asse bly for use again, it must be thoroughly cleaned before it is installed in the transmission. Both reaction surfaces of the disc assembly must be cleaned with emery do. A hand-type sander with 180 grit emery cloth mus be used to clean the disc assembly. Do not use a power sander to clean the

disc assembly. Use the emery cloth either in a clockwise or counterclockwise direction to the diameter of the disc assembly. Do not use the emery cloth in a radial direction to the diameter. After both reaction surfaces are cleaned with emery cloth, the disc assembly must be washed in petroleum based solution 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.

CLEAN DISC ASSEMBUES WITH EMERY CLOTH.

25

HEAT CHECKS

DISC ASSEMBLIES

HEAT CHECKS

Disc assemblies can have fine radial lines or cracks across the reaction surface of a disc. These fine radial lines are heat checks. Disc assemblies that show heat

checks can be used again after they are cleaned. See DISC RECONDITIONING PROCEDURE for the correct method to clean disc assemblies.

REACTION SURFACE OF THE DISC SHOWS HEAT CHECKS. THE DISC CAN BE USED AGAIN AFTER IT IS CLEANED.

USE AGAIN AFTER RECONDITIONING

24

CHIPPED REACTION SURFACE

DISC ASSEMBLIES

DISC ASSEMBL IS CHIPPED ON THE FIRST AND SECOND LAND OF THE OUTSIDE AND INSIDE DIAMETE

DISC ASSEMBLY IS CHIPPED ON THE FIRST AND SECOND LAND OF THE OUTSIDE DIAMETER.

DO NOT USE AGAIN

23

CHIPPED REACTION SURFACE

DISC ASSEMBLIES

CHIPPED REACTION SURFACE

When disc assemblies tum during the operation of the transmission, they can bend a small amount. This can cause a chipped reaction surface where the friction material breaks off. This condition is seen most on the outer edge of the disc assembly.

Some disc assemblies can be chipped and still be used

again. Disc assemblies that are chipped on the first land of the outside diameter, or on the Inside diameter the full 360°, or on any part of the 360°, can be used again.

Never use a disc assembly if the chipped area has extended into the second land on either the outside or the inside diameter.

DISC ASSEMBLY IS CHIPPED ON THE FIRST LAND OF OUTSIDE AND INSIDE DIAMETER.

USE AGAIN

22

EROSION

DISC ASSEMBLIES

DISC ASSEMBLY SHOWS HEAVY EROSION.

DISC ASSEMBLY SHOWS HEAVY EROSION.

DO NOT USE AGAIN

21

EROSION

DISC ASSEMBLIES

EROSION OF REACTION SURFACE

Disc assemblies that show light erosion can be used again. Disc assembJies with heavy erosion must not be used again.

Erosion of the friction material on a reaction surface is normally caused by high temperatures during operation of the transmission.

DISC ASSEMBLY SHOWS LIGHT EROSION.

USE AGAIN

20

GLAZED REACTION SURFACE

DISC ASSEMBLIES

GLAZED REACTION SURFACE

Normal operation of a transmission 'Nill cause a disc CONDITIONI NG PROCEDU RE for the correct method to assembly to beoome glazed and show some discolora- clean disc assemblies. If the disc assembly is not cortion. Disc assemblies that have these characteristics can rectly cleaned before it is used again. it will cause excesbe used again after they are cleaned. See DISC RE- sive slippage during the operation of the transmission.

REACTION SURF CE (FRICTION MATERIAL) OF THE DISC HAS BECOME GLAZED. THE DISC CAN BE USED GAIN AFTER IT IS CLEANED.

THIS IS THE SAME DISC AFTER IT WAS CLEANED.

USE AGAIN AFTER RECONDITIONING

19

TOOTH WEAR

18

DISC ASSEMBL

TOOTH WEAR

Disc assemblies should be inspected for tooth wear.

Never use a disc assembly again that shows tooth wear.

DISC SHOWS TOOTH WEAR.

DO NOT USE AGAIN

FIRST INSPECTION

DISC ASSEMBLIES

FIRST INSPECTION

When the tr~ is disassembled, carefully inspecteach disc assembly. Any disc assembly that is broken, has a crcl:k or deep grooves can not be used again. Look for ee;', that have been broken or have a crack Inspeclhe reaction surfaces tor radial cracks or deep grooves.

DISC ASSEMBLY HAS TWO MARKS TO SHOW THE LOCATION OF CRACKS.

17

NOMENCLATURE AND PATTERNS

DISC ASSEMBLIES

DISC ASSEMBLIES NOMENCLATURE AND PATTERNS

REACTION SURFACE

TOOTH

LAND

OUTSIDE OIAMETER.

INSIDE DIAMETER.

"SPIRAL" PATTERN

16

- ...

"SUNBU.RST" PATTERN

"WAFFLE" PATTERN

"X~GROOVE" PATTERN

POLISHED ~REACTION SURFACE

CLUTCH PLATES

POLISHED REACTION SURFACES

The normal operation of a transmisskm .J] cause the clutch plates and disc assemblies to lear. The top photo shows a new clutch plate. See the ma.rks - ! at were put on

the reaction surface when the plate was machined. Through normal operation these marks will wear away.

i .~

NEW O.......:TGH PLATE SHOWS ORIGINAL MARKS ON THE REACTION SURFAD=_

Do not use clutch plates thai nave a smooth, polished reaction surface. Some clutch p '""::es will have a smooth, polished reaction surface ano e -original marks can still be seen as shown in the bon photo. Other clutch plates will have a smooth, pofished reaction surface and

the original marks will be worn off. Clutch plates th at have a polished reaction surface can be used again after reconditioning,. if the clutch plates are within the specifications for the reconditioning operation,

I 1

CLUTCH PLATE SHOWS A POLISHED REACTION SURFACE. PLATE CAN BE USED AGAIN AFTER RECONDITIONING.

DO NOT USE. AGAIN

15

DO NOT USE AGAIN

SMEARED REACTION SURFACE CLUTCH PLATES

Clutch plates that are heavily smeared must not be be used again after a reconditioning operation. used again. Clutch plates that are heavily smeared can

CLUTCH PLATE IS HEAVILY SMEARED. PLATE CAN BE USED AGAIN AFTER RECONDITION I G.

14

SMEARED REACTION SURFACE

CLUTCH PLATES

SMEARED REACTION SURFACES

Clutch plates will show two types 0 smeared reaction surfaces, light and heavy. Smeared dutch plates have bronze lines on their reaction surfaces. .. caused by the friction material on the disc esse bIies.

Clutch plates that are lightly s eel (narrow cir-

cumferentiallines) can be used a9 . - speed clutches only. Do not use these plates in direcOOnal clutches. See transmission illustrations 2 thru 14' bulletin IDENTIFI-

CATION OF TRANSMISSION CLUTCH PLATES, Form No. SEBF8014 for the correct location of directional clutches. The plate must be installed in the transmission with its reaction surface against the same disc assembly it was in contact with before the plate was removed. If the clutch plate is not installed with the disc assembly, the new disc assembly will wear rapidly.

?tATE IS LIGHTLY SMEARED. MUST BE PUT THROUGH THE ING OPERATION IF USED IN A DIRECTIONAL CLUTCH.

CLUTCH PLATE IS LIGHTLY SMEARED. MUST BE PUT THROUGH THE RECONonO I G OPERATION IF USED IN A DIRECTIONAL CLUTCH.

USE AGAIN IN SPEED CLUTCHES ONLY

13

Use a hand-type sander with 180 grit emery cloth to remove the glaze and for the replacement of some of the grind marks to the high spot area. Use the emery cloth in a radial direction only.

CAUTION

Never use the emery cloth in a Circumferential direction on a clutch plate with a high spot.

HIGH SPOTS CLUTCH PLATES

Clutch plates that show high spots at the reaction difference can be used again after the glaze is removed.

tangs, which are within the specifications for thickness

THE TH ICKNESS DIFFERENCE FOR THIS CLUTCH PLATE IS WITHIN THE SPECIFICATIONS AND CAN BE USED AGAIN AFTER THE GLAZE IS REMOVED.

USE AGAIN AFTER GLAZE IS REMOVED

USE 180 GRIT EMERY CLOTH IN A RADIAL DIRECTION TO REMOVE GLAZE FROM A HIGH SPOT.

12

HIGH SPOTS

CLUTCH PLATES

HIGH SPOTS

Transmission clutch plates that show ahigh spot (shiny surface) and/or a smeared surface in the area of the reaction tang must be checked for a differenoe of thickness before the plates can be used again. Normally, clutch plates that have an indication 0 igh spots at the reaction tangs will have little sign ot wear on the reaction surface between the tangs. Specifications for thickness differences for each clutch plate are given in the Plate

Identification Chart in Bulletin IDENTIFICATION OF TRANSMISSION CLUTCH PLATES, Form No. SEBF8014.

Use a micrometer to measure for thickness differences. Measure the thickness of the reaction surface at a high spot. Also, measure the thickness of the reaction surface half way between the high spot and the next reaction tang.

MEASURE E CLUTCH PLATES FOR A DIFFERENCE OF THICKNESS AT AREAS

A AND B.

Subtract one measuremen 11 the other. This will be more than the given specification, the clutch plate can not

the difference in thickness. easure for a difference of be used again. These plates will cause excessive slipthickness at each high spo on e clutch plate. If the page if they are used again. These clutch plates can be thickness difference at any poi on the clutch plate is put through a reconditioning operation.

THE THICKNESS DIFFERENCE FORTHIS CLUTCH PLATE IS MORE THAN THE GIVEN SPECIFICATION.

DO NOT USE AGAIN

11

DISCOLOAA TION

CLUTCH PLATES

DISCOLORATION

When the transmission is engaged, a small amount of slippage gives a smooth operation to the transmission. When the slippage becomes excessive, friction will cause heat in the clutch plates and disc assemblies. This heat will cause discoloration of the clutch plates and damage the reaction surfaces. Heat can also cause the plates

Clutch plates that show blue-black color can not be put through the reconditioning operation.

and/or discs to warp. Do not use clutch plates that show discoloration. Plates that show light brown, dark brown, light blue or blue can be used again after reconditioning. Plates that have been heated to a blue-black condition can not be put through the reconditioning operation.

Clutch plates that show light brown, dark brown, light blue or blue can be used again after reconditioning.

DO NOT USE AGAIN

10

CIRCUMFERENTIAL GROOVES

CLUTCH PLATES

The inspection of some clutch plates will show the start of circumferential marks, but there will be no grooves. These plates can be used again. These plates must be installed in the transmission so the reaction surface is against the same disc assembly that it was in contact with before the plate was removed. If these plates are not in contact with their original disc assembly, the plates must be put through the reconditioning operation before they

can be used again.

NOTE: Clutch plates with circumferential marks, but with no grooves, must be used in speed clutches only. Do not use these plates in directional clutches. See Transmission, Illustrations 2 thru 14, in bulletin IDENTIFICATION OF TRANSMISSION CLUTCH PLATES, Form No. SEBF80 14 for the correct location of directional cl utches.

CLUTCH PLATE SHOWS CIRCU FERENTIAL MARKS BUT NO GROOVES. THIS PLATE MUST BE PUT THROUGH THE

RECONDITIONING OPERATION IF USED IN A DIRECTIONAL CLUTCH.

USE AGAIN IN SPEED CLUTCHES ONLY

9

CIRCUMFEAENTI'AL GROOVES

CLUTCH PLATES

CIRCUM!FERENTIAL 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 it These clutch plates can be used again only if they are given a reconditioning operation,

PLATE SHOWS CIRCUMFERENTIAL GROOVES, PLATE CAN BE USED AGAIN ONLY AFTER RECONDITIONING,

PLATE SHOWS CIRCUMFERENTIAL GROOVES, PLATE CAN BE USED AGAIN 0 AFTER RECONDITIONING,

DO NOT USE AGAIN

8

EXCESSIVE WEAR

CLUTCH PLATES

EXCESSIVE WEAR

Do not use cI utch plates that show excessive wear on a reaction surface. Excessive wear will cause rapid wear of the disc assembly and can prevent correct operation of the transmission. There is excessive ear if the original grind marks on the reaction surface can not be seen. If a

clutch plate with exoessive wear has the correct thickness, it can be put through the recondition ing operation. If a clutch plate shows the start of wear but the origi nal grind marks can be seen, it can be used again.

CLUTCH PLATE SHOWS EXCESSIVE WEAR. IT CAN BE PUT THROUGH THE RECONDITIONI G OPERATION IF THE THICKNESS IS CORRECT.

DO NOT USE AGAIN

CLUTCH PLATE SHOWS THE START OF WEAR BUT THE ORIGINAL GRIND MARKS CAN BE SEEN.

USE AGAIN

7

REACTION PIN SLOT WEAR

REACTION PIN SLOT WEAR

CLUTCH PLATES

The movement of a transmission clutch plate against a reaction pin will cause wear in the reaction pin slot. This wear must be checked before the clutch plate is installed in the transmission, Excessive wear in the reaction pin slot can cause the reaction tang to break.

To check the pin slot wear, meas re the width of the wear marks. The maximum pe 'SS! idth of the wear marks is 3/16 in. (4.75 mm).lf e eacOOn pin slot wear is

over 3/16 in., the clutch pia e can be used again.

Check the reaction pin slot for ea e bottom. Do nat

use a clutch plate that shows this of wear.

MAXIMUM PIN SLOT WEAR A CLUTCH PLATE CAN HAVE AND STILL BE US~ AGAIN IS 3/16 in, (4.75 mm).

CLUTCH PlATE SHOWS WEAR IN THE BOTTOM OF THE REACTIO PIN SLOT.

DO NOT USE AGAIN

6

FIRST INSPECTION

CLUTCH PLATES

FIRST INSPECTION

When the transmission is disassembled carefully inspect each clutch plate. Any clutch plate that is broken or has a crack can not be used again. Look for reaction tangs that have been broken or have a crack, see illustration on the left, below. Also inspect the eaction surfaces for radial cracks or deep grooves, see Illustration on the

CLUTCH PLATE HAS A BROKEN REACTION TANG.

right, below. These cracks can be large or very small. Be careful of the small cracks. The small cracks can look like the original machined marks. If needed a dye-type penetrant or magnetic particle inspection can be made of the plate to see if there are cracks present.

CLUTCH PLATE HAS A RADIAL CRACK.

DO NOT USE AGAIN

5

NOMENCLATURE

CLUTCH PLATES

r

OUTSIDE DIAMETER.

4

NOMENCLATURE TRANSMISSION CLUTCH PLATE.

ETER.

INTRODUCTION

CLUTCH PLATES AND DISC ASSEMBLIES

INTRODUCTION

The purpose of this booklet is to give a visual com panson of transmission clutch plates and disc assemblies that can be used again in a transmission during the reo conditioning operation. A comparison can be made bet· ween the clutch plates and the disc assemblies removed from a transmission and the illustrations and measurements in this booklet to see if these components can be used again.

Never install a transmission clutch plate or disc assembly that this booklet shows can not be used again.

Many times, the installation of new clutch plates and disc assemblies is not necessary. The installation of used clutch plates and disc assemblies into a transmission during the reconditioning procedure can result in a large reduction in the cost of the rebuilt transmission.

This booklet also gives methods of reconditioning these components to let them be used again in a transmission.

During the transmission reconditioning procedure, correet any conditions that caused the original failure before the transmission is put back into operation.

CAUTION

When a transmission is disassembled, keep the clutch plates and disc assemblies in the original

order In which they were removed. This is Important because some clutch plates or disc assemblies can be used again only in their original location. The failure to follow this caution could cause a failure within the transmission. A 2P5501 Transmission lnternal Parts Rack can be used for storage of plates and discs when the transmission Is disassembled.

There will be many "do not use again" transmission clutch plates. This is not an indication that the clutch plate is scrap. If the clutch plate has the correct thickness, correct flatness and is not broken, it can be used again after it goes through a reconditioning operation.

CAUTION

The wrong method ·01 reconditioning clutch plates can decrease the service life of the plate and/or cause a wrong operation of the transmission which will lead to a failure of the transmission.

The bulletin GUIDELINE FOR REUSABLE PARTS· IDENTIFICATION OF TRANSMISSION CLUTCH PLATES, Form No. SEBF8014 must be used with this booklet for correct specifications and identification of clutch plates.

NOTE: This publication is intended for guidance only and Caterpillar Tractor Co. hereby expressly denies and excludes any representation, warranty or implied warranty of the reuse of transmission clutch plates and/or disc assemblies.

3

GLOSSARY AND INDEX

CLUTCH PLATES AND DISC ASSEMBLIES

GLOSSARY

Chipped: Condition of disc assembly when the friction material is broken off.

Circumferential: Like a circle.

Discoloration: Change in color.

Dish: Bent in the radial direction.

Erosion: Break in the land edges on disc assemblies.

Excessive: Too much.

Flatness: Degree of being flat.

Glazed: Smooth glass type layer.

Heat Checks: Radial cracks in surface of friction material.

Pattern: Design of friction material on disc assemblies.

Polished: Shiny.

Slippage: Clutch plates slide in relation to disc assemblies.

Smeared: Condition of clutch plates shown by bronze lines that come from the friction material on disc assemblies.

Warp: Twisted out of shape, not flat.

INTRODUCTION 3

CLUTCH PLATES

Nomenclature 4

First Inspection 5

Reaction Pin Slot Wear........................................... 6

Excessive Wear 7

Circumferential Grooves 8

Discoloration.......................................................... 10

High Spots................. 11

Smeared Reaction Surface 13

Polished Reaction Surface.................................... 15

2

INDEX

DISC ASSEMBliES

Nomenclature and Patterns 16

First Inspection 17

Tooth Wear 18

Glazed Reaction Surface... 19

Erosion of Reaction Surface 20

Chipped Reaction Surface. 22

Heat Checks.......................................................... 24

DISC RECONDITIONING PROCEDURES 25

Transmission: 31 50, 3155

GUDELINE OR

REUSABLE PARTS

TRANSMISSION CLUTCH PLATES AND DISC ASSEMBLIES

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