CAT 522-5202 SLEEVE-WEAR-GD

CAT 522-5202 is a Caterpillar original GD (General Duty) universal sun gear, adapted for planetary gear transmission systems, used for power transmission under medium to low load conditions. The following is structured raw data, excluding replacement parts information.

Core Technical Parameters (Raw Data)

Item Details
Basic Attributes
Model 522-5202, type is spur sun gear (GD general type), material is 20CrMnTiH alloy steel, carburized and quenched + low temperature tempered, tooth surface hardness HRC 58-62, core hardness HRC 30-40, single weight 2.35 kg, working temperature -40℃ to +120℃, lubrication method is forced grease lubrication, suitable for medium and low speed (≤1500 r/min), medium and low load, stable working conditions, used in gearbox planetary gear trains, final drive planetary sets, etc.

Key Dimensions
Module 3.5 mm, number of teeth 28, pressure angle 20°, addendum circle diameter 105 mm (4.134 in), dedendum circle diameter 87.5 mm (3.445 in), pitch circle diameter 98 mm (3.858 in), tooth width 25 mm (0.984 in). (in), 24 internal spline teeth (DIN 5480 standard), spline minor diameter 48 mm, spline major diameter 52 mm, keyway width 6 mm, depth 3 mm, chamfer at both ends 1×45°, outer diameter tolerance h6, inner diameter tolerance H7. Compatible Machines and Parts: Compatible with the planetary gear sets and final drive planetary mechanisms of the gearboxes of Cat 305.5 and 306 excavators, 416F2 and 420F2 loaders, and 906H and 907H wheel loaders. One planetary gear set per set, capable of withstanding circumferential loads + slight radial loads. Suitable speed ≤1500 r/min, transmitted torque ≤850 N・m. Performance Parameters: Tooth surface contact fatigue strength ≥1100 MPa, tooth root bending fatigue strength ≥650 MPa, transmitted power ≤45 kW, limiting speed 2000 r/min, fatigue life ≥5000 hours, tooth surface roughness Ra≤0.8. μm, tooth direction tolerance ≤0.012 mm, radial runout tolerance ≤0.020 mm
Structural and Performance Advantages

GD Universal Adaptive Design: Optimized for low to medium load conditions, balancing cost and durability, suitable for non-continuous high-load operation equipment, meeting general power transmission needs, and offering high cost-effectiveness.

High-Strength Material and Heat Treatment: Carburized and quenched 20CrMnTiH alloy steel ensures high hardness on the tooth surface for wear resistance, while the core’s toughness absorbs impact, reducing the risk of tooth breakage, suitable for frequent start-stop and small-impact conditions.

Precision Tooth Machining: The tooth profile is ground, achieving tooth direction and pitch accuracy to GB/T 10095.2 Grade 7, ensuring smooth meshing, noise ≤85 dB, reducing transmission loss, and improving transmission efficiency.

Original Factory Compatibility Guarantee: Manufactured by Caterpillar, with dimensions precisely matched to the planetary gears and internal gear ring. The internal spline and input shaft clearance is 0.010-0.020 mm to prevent transmission slippage and uneven tooth surface load, ensuring stable power transmission.

Installation and Maintenance Points (Original Data)

Installation Procedure: Clean the gear surface and internal spline. The internal spline and input shaft interference fit is 0.005-0.015 mm. Assemble using a heat-fit method (heating temperature 80-100℃). After installation, check the tooth surface meshing clearance to be 0.15-0.25 mm and radial runout ≤0.020 mm, ensuring no jamming or tooth misalignment.

Maintenance Cycle: Check lubrication status every 200 hours. Replace grease (Cat 1U-8886 recommended) every 1000 hours. Check tooth surface wear every 4000 hours. Replace when tooth surface wear exceeds 0.20 mm or pitting or peeling occurs.

Common troubleshooting: Insufficient lubrication can lead to tooth surface scuffing and accelerated wear, requiring inspection of the lubrication system; tooth surface pitting is often caused by excessive load and material fatigue, requiring replacement of gears and inspection of planetary gear train fit; spline wear can lead to increased transmission clearance, requiring replacement of gears or input shaft.