SEBF8834 - Brake Clutch Discs and Plates Using Extended Life Friction

04/03/2020 793F CMD Off-Highway Truck (Command for Hauling) RBT00001-UP (MACHINE) POWERED BY C175-16 Engine(SEBP5931 - 1…
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Product: TRUCK
Model: 793F CMD TRUCK RBT
Configuration: 793F CMD Off-Highway Truck (Command for Hauling)
RBT00001-UP (MACHINE) POWERED BY C175-16 Engine
Reuse And Salvage Guidelines

Brake Clutch Discs and Plates Using Extended Life Friction Material{4251, 4255, 4256, 4260,
4267, 4273}
Media Number -SEBF8834-05 Publication Date -03/03/2014 Date Updated -04/03/2014
Caterpillar: Confidential Yellow
i05649030
Brake Clutch Discs and Plates Using Extended Life Friction

Material{4251, 4255, 4256, 4260, 4267, 4273}
SMCS - 4251; 4255; 4256; 4260; 4267; 4273
Off-Highway Truck/Tractor: All
Introduction
Table 1
Revision
Summary of Changes in SEBF8834
05 Added two part numbers.

Updated introduction, added Canceled Part Numbers section, added 163-9366, 9W-7017, 291-
04 2901, 196-7866, 379-1822, 383-2734, and 383-2735 to Table 3, and updated group effectivity.
03 Updated to SIS Authored Format.
© 2014 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 in order to allow a dealer to establish a
parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to
benefit from cost reductions. Every effort has been made in order to provide the most current information
that is known to Caterpillar. Continuing improvement and advancement of product design might have caused
changes to your product which are not included in this publication. This Reuse and Salvage Guideline must
be used with the latest technical information that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for feedback in the Service
Information System. In order to address an urgent issue, use the following resources in order to communicate
your request to Caterpillar Repair Process Engineering: u060ao11
Caterpillar Dealer Technical Communicator
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledp… 1/16
Dealer Solution Network
Caterpillar Technical Representative
Knowledge Network
Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for
information about canceled part numbers and replaced part numbers. NPR will provide the current part
numbers for replaced parts.
Summary
This guideline covers extended life friction material brake discs, as well as the brake plates. Extended life
material is a carbon-based material. All other discs use a paper (cellulose) friction material. Extended life
material provides a significant improvement to brake service life.
The service life of brake assemblies varies due to operating conditions. Careful inspection of all components
should be done during brake service. It may not be necessary to install new discs and plates during a rebuild.
The reuse of discs and plates of acceptable quality can reduce rebuilding costs. This document includes
procedures to recondition otherwise acceptable plates and discs. Do not reuse discs or plates that this
document indicates "cannot be used again" or "Do not use again". Any conditions that caused a failure
must be corrected before reassembly.
References
ReferenceReuse And Salvage Guidelines, SEBF8095, "Service Brakes for Off-Highway Trucks and
Tractors".
Tooling and Equipment

Table 2
Required Tools
Part Number Part Description
- Outside Micrometer
- Depth Micrometer
- Cleaning Equipment
Important Safety Information
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Illustration 1 g02139237
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.
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 warning 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" and followed by a "Signal Word" such as
"WARNING" as shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be wither written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this
publication.
NOTICE
Notice labels in this publication identify operations that may cause
product damage.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are, therefore, not all-inclusive. If a tool, procedure, work method, or
operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and foru060ao11
other people to use. Ensure that the product will not be damaged or be made unsafe by the operation,
lubrication, maintenance, or repair procedures that you choose.
The information, specifications, and illustrations in this publication are based on the information that was
available at the time that the publication was written. The specifications, torque, pressures, measurement,
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 and most current information before you star any job. Caterpillar
dealers have the most current information available.
Safety
NOTICE
Do not operate or work on this product until you have read and
understood the operation, lubrication, maintenance, and repair
information. Failure to follow the instructions for operation,
lubrication, maintenance, or repair of this product could result in
injury or death.
Hot oil and components can cause personal injury. Do not allow hot oil
or components to contact skin.
Always use a board or cardboard when checking for a leak. Escaping

fluid under pressure, even a pinhole size leak, can penetrate body
tissue, causing serious injury and possibly death. If fluid is injected into
the skin, a doctor familiar with this type of injury must remove it
within few hours.
Brake Service Concerns

During brake service, care must be taken when handling and storing discs and plates. Do not stack them
unless they are protected by original packaging. Friction material can be chipped from disc surfaces if they
are struck by each other or other hard objects. Plate surfaces can be scratched by contact with other plates or
similar objects. Light scratches may be smoothed over by brake application (refer to Illustration 10), but
deeper scratches will tend to scrape friction material from the disc. The recommended storage method for
loose discs and plates is to hang them on hooks individually.
Because of the difference in material wear rates, do not mix discs of paper and extended life friction material
when rebuilding a brake assembly. When replacing complete brake assemblies on a given machine, the use
of assemblies with different materials is permitted.
Brake Plate Cleaning and Inspection

Before doing a thorough cleaning, brake plates can be wiped with a cloth and checked for obvious conditions
that prevent their reuse. Do not use again the plate, if any cracks are seen. Some spline wear is acceptable,
but any plates with broken spline teeth or splines that have wear notches, must be scrapped. Refer to
Illustration 3 through Illustration 5 for sketches of spline wear (the original surfaces are shown as dotted
lines).
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Acceptable (internal) spline surface wear.
Acceptable (external) spline surface wear.
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Unacceptable spline wear.
Wear has progressed to the point where notches are present (refer to Illustration 5). Because the stress
concentrated in these areas will likely result in cracks and broken splines. Do not use again the plate or disc.
Plates found acceptable during the initial inspection should be cleaned with a suitable solvent. Use a clean
cloth or compressed air to dry the plates. Use dye penetrant or other equipment to check for cracks which
may not be visible. Be sure to follow the instructions for the crack check equipment you are using. If cracks
found anywhere on the plate, then the plate should be scrapped. Inspect the spline areas closely.
NOTICE
Use all cleaning solvents and solutions with care. Wear eye and ear
protection when using high-pressure cleaning equipment. Always use
cleaning solvents in a well ventilated area. Always wear protective
clothing when using caustic cleaning solutions. Failure to follow the
precautions provided by the manufacturer of the cleaning equipment,
and/or solvents, can result in bodily injury.
Pressurized air can cause personal injury. When using pressurized air
for cleaning or drying parts, wear a protective face shield, protective
clothing, and protective shoes. The maximum air pressure must be
below 200 kPa (29 psi).
The plate must also be checked to see if it is warped. The plate must be flattened by applying a 9.1 kg (20 lb)
weight fixture, so that a 0.038 mm (0.0015 inch) feeler gauge will not fit between the plate and the surface
plate. Brake plates that do not meet this specification must be scrapped. Weight fixtures can be fabricated
from steel plate that is flame cut to the approximate diameter of the brake plate contact surface, and
deburred. Enough weight to reach the 9.1 kg (20 lb) total should be placed on the top. If the weight is welded
to the plate, the bottom surface may require grinding if it becomes warped due to heat. Illustration 6 is a
sketch of the weight fixture and flatness test.
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Checking warp of brake plate.
(1) Surface plate
(2) Brake plate
(3) Plate test weight.
(4) Steel scrap, to provide 9.1 kg (20 lb) test plate weight.
(5) Eyebolt for lifting test plate, if desired.
If a 0.038 mm (0.0015 inch) feeler gauge can be inserted between the brake plate and surface table with the
test weight applied, the plate must be scrapped.
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Excessive damage to plate contact surface. The friction material had worn from the adjacent disc, resulting in metal-to-metal
smearing.
Do not use again
Excessive contact surface grooving.
Do not use again
Overheated contact surface of sectioned disc, with local hot spots.
Do not use again
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Lightly worn plate contact surface. Arrow indicates scratch and slightly darker metal smear pattern extending to left after scratch.
Use again
The scratch was caused by contact with another plate or other hard object before brake assembly. This
scratch was not bad enough to prevent use of this plate (refer to illustration 10), but a heavier scratch could
dig into disc friction material and cause early brake assembly failure.
Use a micrometer to measure the plate thickness. Do not use again the plate, if the thickness is below the
minimum level given in Table 3. Do not use again the plate, if surface damage is more than 10% (refer to
Illustration 7). Used plates may also have deep radial grooves as shown in Illustration 8. Because deep
grooves accelerate wear of the friction material, these plates must not be reused. Illustration 10 shows a
lightly worn contact surface, which was scratched before assembly. This scratch was not deep enough to
result in brake assembly failure, but deeper scratches could have caused rapid wear of disc friction material.
Plates that have been subjected to extreme overheating will have uneven discolored spots as shown in
Illustration 9, and must not be reused. Refinishing plate surfaces is not possible, since the thickness tolerance
does not allow enough stock.
Table 3
Plate Dimensions
Plate P/N Disc P/N New Plate Thickness Min. Plate Thickness
8W-0212 190-3532
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
8X-4437 221-0775
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
7D-7671 196-7886
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
7D-7504 222-2333
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
8W-0212 226-2826
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch) u060ao11
163-9366 9W-7017 Caterpillar: Confidential Yellow
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
163-9366 196-7866
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
163-9366 291-2901
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
379-1822 383-2734
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
379-1822 383-2735
2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)
198-1203 207-1266
2.704 ± 0.064 mm (0.1064 ± 0.0025 inch) 2.64 mm (0.1039 inch)
145-5189 207-1265
4.000 ± 0.080 mm (0.1575 ± 0.0032 inch) 3.920 mm (0.1543 inch)
Table 4
5.08 mm (0.200 inch) Disc Thickness Wear

Percent Life Remaining Disc Thickness Disc Groove Depth
100
5.08 mm (0.200 inch) 0.64 mm (0.025 inch)
90
5.03 mm (0.198 inch) 0.62 mm (0.024 inch)
80
4.98 mm (0.196 inch) 0.60 mm (0.024 inch)
70
4.93 mm (0.194 inch) 0.59 mm (0.023 inch)
60
4.88 mm (0.192 inch) 0.57 mm (0.022 inch)
50
4.83 mm (0.190 inch) 0.55 mm (0.022 inch)
40
4.78 mm (0.188 inch) 0.53 mm (0.021 inch)
30
4.72 mm (0.186 inch) 0.51 mm (0.020 inch)
20
4.67 mm (0.184 inch) 0.50 mm (0.020 inch)
10
4.62 mm (0.182 inch) 0.48 mm (0.019 inch)
0
4.57 mm (0.180 inch) 0.46 mm (0.018 inch)
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Table 5 Caterpillar: Confidential Yellow
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6.05 mm (0.238 inch) Disc Thickness Wear

Percent Life Remaining Disc Thickness Disc Groove Depth
100
6.05 mm (0.238 inch) 1.050 mm (0.0413 inch)
90
6.00 mm (0.236 inch) 1.025 mm (0.0403 inch)
80
5.95 mm (0.234 inch) 1.000 mm (0.0394 inch)
70
5.90 mm (0.232 inch) 0.975 mm (0.0384 inch)
60
5.85 mm (0.230 inch) 0.950 mm (0.0374 inch)
50
5.80 mm (0.228 inch) 0.925 mm (0.0364 inch)
40
5.75 mm (0.226 inch) 0.900 mm (0.0354 inch)
30
5.70 mm (0.224 inch) 0.875 mm (0.0344 inch)
20
5.65 mm (0.222 inch) 0.850 mm (0.0335 inch)
10
5.60 mm (0.220 inch) 0.825 mm (0.0325 inch)
0
5.55 mm (0.218 inch) 0.800 mm (0.0315 inch)
Extended Life Friction Material Discs
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New, extended life friction material disc.
To avoid chipping of friction material and other damage, handle unpackaged discs carefully. Do not stack the
discs during brake service. The recommended storage method is to hang the discs on hooks. A new disc is
shown in Illustration 11. This material has a gray appearance when new. The color of used discs is not a good
indicator of reusability.
Discs should be checked first for the following conditions that prevent reuse of the discs. Discs with areas of
missing friction material, or any material that has separated from the steel core, must be scrapped. Check for
cracked or notched splines, as explained in the ""Brake Plate Cleaning and Inspection" " section of this
guideline. Discs that have been overheated due to prolonged brake application or insufficient cooling oil flow
may become warped or glazed. Glazing hardens the friction material and causes a shiny, solid surface as
compared to the dull, porous appearance of a new disc. Scrap any glazed discs.
If the lube system oil has been contaminated by water or antifreeze, the discs must also be scrapped.
If otherwise acceptable, the discs should be cleaned for closer inspection. The recommended cleaning
method for extended life friction material discs is to wipe the discs with a dry shop towel, or a towel dipped
in ethanol, methanol, or isopropyl alcohol. Discs should not be soaked in alcohol, because the alcohol can be
absorbed into the friction material. Dry the discs with a clean towel or compressed air.
NOTICE
Never clean discs with water, steam, water-based solutions, Freon,
paint thinner, or ketones. These liquids can react with the friction
material and degrade the bond between the friction material and the
steel core.
Discs may have material eroded from the edges of the contact surfaces. Areas of eroded or chipped friction
material do not prevent disc reuse, but these areas must be less than 10% of the total contact surface area. Do
not reuse a disc if the friction material can easily be chipped from the surface with the point of a knife or box
cutter. Refer to Illustration 12 through Illustration 1 for examples of disc wear.
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Material bond has failed Caterpillar: Confidential Yellow
Do not use again
Used, extended life friction material disc: Acceptable amount of wear, if thickness is within specification.
Use again
Closer view of a used disc: Acceptable amount of wear, if thickness is within specification.
Use again
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Disc has more wear than Illustration 13, but is still acceptable if thickness is within specification.
Use again
Closer view of a used disc, showing erosion that is greater than 10% of contact surface.
Do not use again
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Example of chipped friction material. Although the damage to this disc is not severe enough to prevent reuse, care should always be
taken during storage and handling.
Use again
Sketch of disc, showing side-to-side friction material and groove thickness measurements. Measurements (A) and (C) must be 50%
or greater than measurements (B) and (D), respectively. This is necessary to ensure adequate flow of cooling oil through the grooves
in the thinner side.
If contact surface is acceptable, use an outside micrometer to check overall disc thickness. Use a depthu060ao11
micrometer to check friction material wear on both sides of the disc. Disc groove Caterpillar: Confidential Yellow
depth is also checked with
a depth micrometer.
Refer to Table 4 and Table 5 for original and minimum remaining disc life, based on friction material and
groove depth measurements.
Friction material wear should not be excessive on one side of the disc. Do not use again the disc, if the
thickness measurement on one side is ½ or less than the measurement of the other side. Refer to Illustration
1.
If discs are found to be acceptable for reuse, they must be oriented to the hub splines as they were originally
found. The disc splines that were located over the hub lube slots will have no wear. These unworn splines
must be reinstalled in the lube slots. If the brake is reassembled with unworn disc splines contacting hub
splines, the unworn splines will be subjected to much heavier loads during brake application. These heavily
loaded splines may break off the disc.
Write down the measured remaining life of discs in the assembly and compare them. There is a maximum of
20% difference in wear between reusable discs. For example, do not reuse a group of discs with 50%, 70%,
and 80% remaining life. Do not install a new disc with a used disc that has 70% life remaining.
NOTICE
Do not mix discs of paper (cellulose) and extended life friction material
when rebuilding a brake assembly. Complete brake assemblies using
different friction materials may be mixed in a given machine.
NOTICE
If new discs and discs with significant wear are used in a brake
assembly, the worn discs may not receive sufficient cooling oil flow due
to their smaller groove size. This can cause rapid overheating and
failure of the worn discs. For this reason, a maximum difference of
20% wear is allowed between discs to be reused in a brake assembly.
Also, any discs acceptable for reuse must have their unworn (lube slot)
splines oriented to the hub as they were originally found.
Copyright 1993 - 2020 Caterpillar Inc. Wed Mar 04 2020 22:31:39 GMT-0300 (Horário Padrão de Brasília)
All Rights Reserved.
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04/03/2020 793F CMD Off-Highway Truck (Command for Hauling) RBT00001-UP (MACHINE) POWERED BY C175-16 Engine(SEBP5931 - 1…

Reuse And Salvage Guidelines

Brake Clutch Discs and Plates Using Extended Life Friction

Off-Highway Truck/Tractor: All

05 Added two part numbers.

03 Updated to SIS Authored Format.

Dealer Solution Network

Caterpillar Technical Representative

Canceled Part Numbers and Replaced Part Numbers

Tooling and Equipment

Important Safety Information

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

Always use a board or cardboard when checking for a leak. Escaping

Brake Service Concerns

Brake Plate Cleaning and Inspection

(1) Surface plate

(2) Brake plate

(3) Plate test weight.

(5) Eyebolt for lifting test plate, if desired.

Do not use again

Do not use again

Do not use again

2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) 2.349 mm (0.0925 inch)

5.08 mm (0.200 inch) Disc Thickness Wear

6.05 mm (0.238 inch) Disc Thickness Wear

Extended Life Friction Material Discs

Do not use again

Do not use again

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