ITOT WIZEI

GU1DA NCE
FOR
REUSABLE PARTS

PLANETARY GEAR
TRANSMISSION
 INDEX

INTRODUCTION .............................................................. 1

MAIN CAUSES OF DAMAGE .......................................... 2

JUDGEMENT ABOUT DAMAGE ......................................... 3

 Check points when judging parts

JUDGEMENT STANDARDS ....................................... 6

 Judgement standards for reuse

EXAMPLES OF DAMAGE ................................................... 9

 Housing
 Piston
 Torque pin
 Carrier
 Planet gear shaft
 Planet gear
 Thrust washer
 Drive shaft
 Output shaft
 Ring gear
 Seal ring
 Needle bearing
 Coupling

PREVENTIVE MAINTENANCE ........................................ 28

 INTRODUCT1ON
This Guidance for Reusable Parts of the planetary gear transmis-
sion gives the knowledge of the basic structure and explanation of
the causes of damage needed when carrying out disassembly and as-
sembly or repairs of the TORQFLOW transmission. It also gives
photographs with examples of damage to make it possible to judge
easily whether a part can be used again or not.
This Guidance for Reusable Parts is designed to be used by a wide
range of people dealing with repairs and maintenance.
We hope that the information will be used to reduce repair costs
by distinguishing between parts that can be reused and those that
must be replaced. We also hope that it will contribute towards pre-
vention of reoccurrence of problems.

Note: This publication is intended for guidance only and KOMATSU LTD. hereby
expressly denies and excludes any representation, wa rranty or implied war-
ranty for the reuse of planetary gear transmission.

1
 MAIN CAUSES OF DAMAGE
Damage and drop in performance arise when various problems occur together.
With the transmission, improper maintenance of the oil (oil level, oil pressure, dirt in
oil) and improper operation (overloading, overrunning, sudden starting) are the most
common factors causing damage.

operation
The planetary gear transmission can be shifted without stopping the machine
(except for dump trucks traveling in reverse). However, if the gear is suddenly shifted
from the highest forward speed to reverse (or vice versa), there is an excessively high
load brought to bear on the transmission.

On downhill slopes, if the speed for the selected speed range is exceeded, the in-
ternal parts of the transmission will rotate at abnormally high speed (overrunning).
With dump trucks, if the dump truck is overloaded, an excessive force is brought to
bear on the transmission.

In all of these cases, a load exceeding the permitted limit is brought to bear on
various parts, so if this is repeated, the performance will drop, or parts will be
damaged.

Oil Level
If the oil level is too low, and the machine is on even a slight slope, the pump will
suck in air, and the hydraulic pressure will drop. This causes damage to the clutch.
In addition, the oil will become dirty and will deteriorate quickly, so this will cause
wear and damage.

Oil Change
1f proper oil changes are not carried out, the oil will become dirty and will deterio-
rate, and this will cause wear and damage.

Oil Temperature
If the proper speed range of the transmission is not selected (Note 1), and the
machine continues to be operated with the oil at an abnormally high temperature,
the seals (oil seals, seal rings, O-rings) will harden and this will cause oil leakage. It
will also increase the speed of deterioration of the oil, and this will cause wear and
damage.

Note 1 : This section does not apply to automatic transmissions.

Entry of Dirt
If dirt or dust gets into the oil (particularly when changing the oil), this will cause
wear of parts and defectiva function of the valves.
 JUDGEMENT ABOUT DAMAGE
When judging whether a part can be reused again, it is necessary to consider the daily
maintenance and operating conditions to determine why such damage occurred, and to
follow up the cause. This manual gives photographs ranking the damage into categories A,
B, and C. These photographs should be used together with the know -how obtained from
long years of experience to judge if the part can be reused.

Check Points when Judging Parts

To make accurate judgement on damaged parts, the part must first be thoroughly washed
and cleaned, and then the following check points must be considered carefully. In the case of
some parts, there may be no applicable check points given.

Part Check point Part Check point

Housing  Wear and damage Disc  See Disc and Plate
of seal ring contact Volume
s ur fac e
 Wear and damage
$114 of d is c c ontac t
3'
3
\• s ur fac e 5E1
ll
ir '
 Wear and damage
 of inside and outside
I .%
o'i
s ur f a c e of p is to n
I :111
it) insertion portion
 Wear and damage
%
of ring gear sliding
4411bas■ s ur fac e

Piston  Wear and damage Plate  See Disc and Plate

, of d is c c ontac t Volume
s ur fac e
,

 Wear of inside and

outside surface of
pistan portion • Settling of torque pin
hole

e ,
 Part Check point Part Check point
Carrier  Settling of shaft Thrust washer  Wear and damage
hale of side surface
■ Surface roughness
and damage of
thrust washer
/12.1 '', contact surface
 Settling of
i
■:.‘• spline
 Wear and damage
of seal ring contact
surface

Planet gear  Damage, flaking, Needle bearing  Flaking of needie

shaft wear of bearing  Cracking of cage
rolling surface
 Wear of thrust
washer contact
surface
" yffigh
Alffla mons
"' gil W I M M
1~1.
IMIN

Planet  Wear of thrust Bearing  See Bearing

gear washer contact Volume
surface
 Flaking and damage
of bearing rolling ■101,
surface r
11W._  For details of teeth, f
l
see Gear Volume
_ ,

1 111

4
 Part Check point Part Check point
Drive shaft  Wear and damage Collar  Wear of seal ring
of seal ring groove groove
 Settling of ■ Wear of spline
spline
■ Cracking of spline
it tooth bottorn, 1,
.,1.
/// stepped portion
■ Cracking at mouth
ni ,
1

of drill hale ))
W /
-‘/
4
Drive  See Gear Volume Seal ring  Breakage at end
gear gap
 Wear of outside
circumference and
side surface

- to)"
 Damage of housing Coupling  Wear of oil seal
Ring
gear sliding surface (side contact surface
surface)  Wear of spline
 Wear of inner teeth
 Wear of outer teeth

.r
w z
w
ftir
il
-..-=_.

5
 NORMAS DE JUICIO

Categoria Daño estandar Remedio

La parte es tan buena como nueva; no hay problema para el

Se puede usar
rendimiento de la máquina; No hay riesgo de daño secundario
A como está
causado por este daño.

Si esta parte se usa como está, el daño progresará y existe el riesgo Reparación y
de que pueda causar un daño secundario. Si la pieza se reencuentro
B
reconstruye, puede mantener la función de la máquina.

La pieza no se puede reparar, el defecto claramente causará una

No se puede
caída en el rendimiento de la máquina y existe el peligro de que
C reutilizar
pueda causar daños graves si se usa
.

NORMAS DE JUICIO PARA LA REUTILIZACIÓN

Las siguientes normas se aplican al juzgar si alguna parte puede reutilizarse.
Cuando hay más de un tipo de daño en la misma parte, juzgue la categoría de acuerdo con la
condición del daño más grave.
(Ejemplo: si dos tipos de daños se clasifican respectivamente como A y B, clasifique la parte como
categoría B.)

Comprobar Juicio
Parte
Nombre Posición c
A B
 Superficie  Daño leve y
Contacto leve desgaste
deslizante de rugosidad de
corona dentada la superficie
Contacto leve desgaste
 Daño leve y
 porción de rugosidad de
Carcaza

inserción del Contacto leve la superficie

pistón desgaste
 Contacto de
disco  Daño leve,
Desgaste, daño
 superficie Contacto leve aspereza
Superficie de contacto superficial y
del anillo de sello decoloración
—
Daño leve, aspereza
superficie de contacto
Contacto leve superficial y desgaste
Piston

del disco Deformación

■ agujero de pasador de decoloración.
torque Contacto leve
—

6
* Consulte los valores en el Manual de taller para conocer el límite de espacio entre el pistón y la
porción de insercin de la carcasa.
 J U I C I O
Parte
Comprobar posicion
Nombre
A B C
asentamiento
 Agujero del eje _
Contacto leve
— rugosidad de la superficie,
 Superficie de la Contacto leve daños
i)
r. arandela de
1 empuje — asentamiento
0
Contacto leve —
 ranura desgaste, daño

 superficie de Contacto leve

contacto del
anillo de sello
Contacto leve Descamación,
 superficie de — desgaste, daños
rodamiento
— Desgaste escalonado
cu Contacto leve
+., -c  superfivcie de
o contacto de la
ro °3 arandela de
Eg empuje —

Contacto leve — Descamación,daño

 Bearing rolling
....
c .- surface
o In
E. 41
 Thrust washer Contacto leve daños
el'
contact surface

Superficie lateral Contacto leve — Desgaste escalonado

c
a) el
• a gu j a Contacto leve — Descamacion
V:i-—
4>1 Normal — agrietamient
zCDo . 0 • Jaula
o
Contacto leve — Solución de
 Porción de diente
4... estriado
..- Norm al grietas
.c  Porción de diente
o
o estriado No r m al — Agrietamiento

 Porción de diente Norm al

Ci Daño agrietado,
estriado
Normal — rebabas
 P o r c ió n es c alo n a da

 Ranur a del an illo

de s ello
—

—
7
 J u d g e m e n t
Part Check
Name Position
A B C
Engranaje de anillo

 Dientes internos Contacto leve — desgaste

 D i en t es ext er n o s Contacto leve — desgaste

 Superficie
deslizante de la
Contacto leve — Daños
carcaza
(superficie sida)
 Ranura de anillo
Normal
— Daños, rebabas
Jelio3

de sello
Contacto leve
— asentamiento
 ■ ranura

— Rotura
Anillo de sello

 Fin de la brecha Normal

— desgaste
 Superficie lateral Contacto leve
 Circunferencia exterior Contacto leve — desgaste

 Superficie de Contacto leve Mas que 0.05 Mas que 0.05

contacto del mm desgaste mm desgaste
6u!idno3

sello de aceite
Contacto leve asentamiento
 ranura

* Consulte los valores en el Manual de taller para conocer el límite de servicio del desgaste del anillo de sello