- Articulated Truck:
- 725 (S/N: WWA1-UP; B1L1-UP; AFX1-UP)
- 730 (S/N: WWB1-UP; AGF1-UP; B1M1-UP)
- 730 EJECTOR (S/N: B1M1-UP; B1W1-UP)
- 735 (S/N: AWR1-UP)
- 740 (S/N: WWD1-UP; AXM1-UP; B1P1-UP; DTX1-UP; AZZ1-UP)
- 740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)
- D20D (S/N: 9MG1-UP)
- D250B (S/N: 5WD1-UP)
- D250D (S/N: 6NG1-UP)
- D250E Series II (S/N: 4PS1-UP)
- D250E (S/N: 5TN1-UP)
- D25C (S/N: 9YC1-UP)
- D25D (S/N: 1HK1-UP)
- D300B (S/N: 4SD1-UP)
- D300D (S/N: 5MG1-UP)
- D300E Series II (S/N: 5KS1-UP)
- D300E (S/N: 7FN1-UP)
- D30C (S/N: 7ZC1-UP)
- D30D (S/N: 3AJ1-UP)
- D35-HP (S/N: 3FD1-UP)
- D350C (S/N: 8XC1-UP)
- D350D (S/N: 9RF1-UP)
- D350E Series II (S/N: 2XW1-UP)
- D350E (S/N: 9LR1-UP)
- D35C (S/N: 2GD1-UP)
- D400 (S/N: 1MD1-UP)
- D400D (S/N: 8TF1-UP)
- D400E Series II (S/N: APF1-UP; 8PS1-UP)
- D400E (S/N: 2YR1-UP)
- D40D (S/N: 2JJ1-UP)
- D44B (S/N: 8SD1-UP)
- D550B (S/N: 5ND1-UP)
- 730 (S/N: WWB1-UP; AGF1-UP; B1M1-UP)
Introduction
Revision     | Summary of Changes in SEBF2191     |
02     | Changed supplier name from Sulzer Metco to Oerlikon Metco.     |
01     | Added confidentiality statement, Think Safety graphic, and updated Praxair TAFA arc spray system.     |
00     | Information removed from SERF8473 (Arc Spray Guide CD) and SERF8704 (Flame Spray Guide CD) and formatted for delivery in SIS.     |
© 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 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 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. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:
- Caterpillar Dealer Technical Communicator
- Dealer Solution Network
- Caterpillar Technical Representative
- Knowledge Network
For further information on the equipment needed to perform thermal spray processes, refer to the following publications:
- Special Instruction, SEBF9236, "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components"
- Special Instruction, SEBF9238, "Fundamentals of Arc Spray for Reconditioning Components"
- Special Instruction, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components"
Canceled Part Numbers and Replaced Part Numbers
This document may not 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.
Important Safety Information
Illustration 1 | g02139237 |
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 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 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 recommended by Caterpillar is used, ensure that the procedure is safe for you and for other people to use. 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.
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 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.
Illustration 2 | g03127287 |
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. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, or the repair procedures will not make the machine unsafe.
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.
Part Description
Base Metal     | SAE 4118     |
Hardness     | 28-34 Rc     |
Arc Spray Equipment and Procedure
Maximum Surface Finish     | 1.6 Micrometer (63 Microinch)     |
Reason for Spraying     | Wear     |
Mating Part Contact Area & Material     | Bearing     |
Arc Spray Equipment Type     | SmartArc byOerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU     |
Wire     | TAFA 90MXC Wire Top Coat, TAFA 75B Bond Coat     |
Finish Thickness     | As Required     |
Spray Angle     | 90°     |
Substrate Pre-Heat Temperature     | 66° C (150° F) Do not direct arc on area to be sprayed     |
Substrate Temperature During Spraying Not to Exceed     | 148° C (300° F)     |
Auxiliary Cooling     | Filtered shop air     |
Rotation/Traverse Device     | Lathe     |
Rotation Speed     | 92.0 SMPM (300.00 SFPM)     |
Surface Preparation Method     | Undercut and Grit blast     |
Equipment Required     | Horizontal Split - Bed Lathe or Vertical Lathe     |
Recommended Cutting Tool     | ISCAR DNMG 432TFIC507     |
Blast Media Recommendation     | Pressure Type Only (Aluminum Oxide Grit)     |
Remarks     | Refer to Special Instruction, SEHS9807, "ADT Hitch/Rear Frame Salvage"     |
Arc Spray     | Procedure     | Check List     | ||
Clean Part     | Degrease in hot Aluminum safe cleaner     |     | ||
Undercut     | If desired     |     | ||
Remove Oxide     | Use emery cloth or glass bead blaster     |     | ||
Clean Spray Area     | Commercial degreaser     |     | ||
Mask for Grit Blaster     | Duct tape, metal shield, or rubber     |     | ||
Grit Blast Equipment     | Pressure type only     |     | ||
Grit Type and Size     | 20 mesh aluminum oxide     |     | ||
Blast Air Pressure     | 690 kPa (100.0 psi)     |
    | ||
Blast Nozzle to Work Distance     | 51 to 150 mm (2.0 to 6.0 inch)     |
    | ||
Remove Blast Mask     | Remove mask material, make sure that surface is clean     |     | ||
Mask for Metal Spray     | Duct tape, metal shield, or rubber     |     | ||
Metal Spray Equipment Type     | Smart Arc by Oerlikon Metco     | TAFA     |     | |
    | Consumable (Bondcoat)     | TAFA 75B     | TAFA 75B     |     |
    | Clamp Pressure     | 275 kPa (40 psi)     |
    |     |
    | Air Jets/Pressure     | 415 kPa (60 psi)     |
415 kPa (60 psi)     |
    |
    | Arc Load Volts     | 30V     | 30V     |     |
    | Amps     | 125 Amps     | 150 Amps     |     |
    | Gun to Work Distance (Standoff)     | 128 mm (5.0 inch)     |
128 mm (5.0 inch)     |
    |
    | Spray Rate/Bond Pass     | 0.038 mm (0.0015 inch)/pass     |
0.038 mm (0.0015 inch)/pass     |
    |
    | Consumable (Topcoat)     | TAFA 90 MXC     | TAFA 90 MXC     |     |
    | Clamp Pressure     | 275 kPa (40 psi)     |
    |     |
    | Air Jets/Pressure     | 415 kPa (60 psi)     |
415 kPa (60 psi)     |
    |
    | Arc Load Volts     | 32V     | 32V     |     |
    | Amps     | 125 Amps     | 150 Amps     |     |
    | Gun to Work Distance (Standoff)     | 102 mm (4.0 inch)     |
102 mm (4.0 inch)     |
    |
    | Spray Rate/Build Up     | 0.038 mm (0.0015 inch)/pass     |
0.038 mm (0.0015 inch)/pass     |
    |
    | Rotation Speed of Part (RPM)     | RPM varies depending on diameter     |     | |
    | Rotation Speed of Part     | 92.0 SMPM (300.00 SFPM)     |
    | |
    | Traverse Rate of Gun     | 11.0 SMPM (40.00 SFPM)     |
    | |
Gun Fixturing Method     | Machine mount or hand held     |     | ||
Finishing Equipment     | Hot Split Bed Lathe or Vertical Lathe     |     | ||
Part/Cutter Rotation Roughing     | 50.0 SMPM (150.00 SFPM)     |
    | ||
Part/Cutter Rotation Finishing     | 75.0 SMPM (250.00 SFPM)     |
    | ||
Coolant     | Oil base synthetic - 40:1 ratio     |     | ||
Traverse Speed     | 0.30 mm (0.012 inch)     |
    | ||
Depth of Rough Cut     | 0.51 mm (0.020 inch)     |
    | ||
Depth of Finish Cut     | 0.25 mm (0.010 inch)     |
    |
Flame Spray Equipment and Procedure
Maximum Surface Finish     | 1.6 Micrometer (63 Microinch)     |
Reason for Spraying     | Wear     |
Mating Part Contact Area & Material     | Bushing     |
Metco Equipment Type     | 6P-II by Oerlikon Metco     |
Metco Material     | Metco 453     |
Finish Thickness     | As Required     |
Finishing Allowance     | Min. of 1.78 mm (0.070 inch) per side     |
Spray Angle     | 90°     |
Substrate Pre-Heat Temperature     | 66° C (150° F) Do not direct flame on area to be sprayed     |
Substrate Temperature During Spraying Not to Exceed     | 148° C (300° F)     |
Auxiliary Cooling     | If desired     |
Rotation/Traverse Device     | Horizontal Split - Bed Lathe or Vertical Lathe     |
Rotation/Traverse Speed     | 91.4 SMPM (300.00 SFPM)     |
Surface Preparation Method     | Grit Blast     |
Finishing Method     | Machine     |
Machining Equipment Type     | Horizontal Split - Bed Lathe or Vertical Lathe     |
Recommended Cutter Grade     | C-2, 883 Carboloy or equivalent     |
Remarks     | Refer to Special Instruction, SEHS9807, "ADT Hitch/Rear Frame Salvage"     |
Flame Spray Process (6P)     | Procedure     | Check List     |
Clean Part     | Degrease in hot caustic solution     |     |
Undercut     | To "tru-up" surface     |     |
Remove Oxide     | Use fiber flap brush or Clean/strip disc     |     |
Clean Spray Area     | Metco cleaning solvent or equivalent     |     |
Mask for Blast     | Duct Tape     |     |
Blast Equipment     | Pressure type only     |     |
Grit Type and Size     | 24 mesh Aluminum Oxide     |     |
Blast Air Pressure     | 690 kPa (100.0 psi)     |
    |
Blast Nozzle to Work Distance     | 50 to 150 mm (2.0 to 6.0 inch)     |
    |
Remove Blast Mask     | Remove mask, make sure that surface is clean     |     |
Mask for Spray     | Metco Antibond or Blue Layout Dye     |     |
Spray Equipment Type     | 6P-II Hand Held Thermo Spray System by Oerlikon Metco     |     |
Auxiliary Cooling     | If desired     |     |
Nozzle     | 6P-C7A-K "K" Nozzle     |     |
Air Capacity/Pressure     | 6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)     |
    |
Oxygen Pressure     | 210 kPa (30.0 psi)     |
    |
Oxygen Flow     | 1190 L/h (42.0 cfh)     |
    |
Fuel Gas Pressure     | 100 kPa (15.0 psi)     |
    |
Fuel Gas Flow     | 1415 L/h (50.0 cfh)     |
    |
Carrier Gas Pressure     | 380 kPa (55.0 psi)     |
    |
Carrier Gas Flow     | 1050 L/h (37.0 cfh)     |
    |
Spray Rate/Build Up     | 5.5 kg (12 lb) per hour or 90 gr (3.2 oz) per min     |
    |
Gun to Work Distance     | 230 mm (9.0 inch)     |
    |
Rotation Speed Of Part (RPM)     | RPM varies depending on diameter     |     |
Rotation Speed Of Part     | 91.4 SMPM (300.00 SFPM)     |
    |
Traverse Rate of Gun     | 15.24 SMPM (50.000 SFPM)     |
    |
Gun Fixturing Method     | Machine mount or hand held     |     |
Top Coat/Thickness     | 0.10 to 0.15 mm (0.004 to 0.006 inch) per pass     |
    |
Finishing Equipment     | Lathe     |     |
Part/Cutter Rotation     | 91.4 SMPM (300.00 SFPM)     |
    |
Traverse Speed     | 0.05 to 0.10 mm (0.002 to 0.004 inch) per revolution     |
    |
Depth of Rough Cut     | 0.38 to 0.51 mm (0.015 to 0.020 inch) per side     |
    |
Depth of Finish Cut     | 0.25 to 0.38 mm (0.010 to 0.015 inch) per side     |
    |
Additional Finish Method     | Emery cloth for desired finish     |     |
Specifications
Illustration 3 | g03127315 |
ADT Hitch Salvage Dimensions     | |||
Part No.     | Dimension A     | Dimension B     | Dimension C     |
117-1778     | 508.025 ± 0.250 mm (20.0010 ± 0.0100 inch)     |
266.36 ± 0.04 mm (10.487 ± 0.002 inch)     |
15.0 ± 1.0 mm (0.59 ± 0.04 inch)     |
7U-7377     | 511.025 ± 0.025 mm (20.119 ± 0.0010 inch)     |
266.36 ± 0.04 mm (10.487 ± 0.002 inch)     |
15.0 ± 1.0 mm (0.59 ± 0.04 inch)     |
7U-0807     | 511.025 ± 0.025 mm (20.119 ± 0.0010 inch)     |
266.36 ± 0.04 mm (10.487 ± 0.002 inch)     |
15.0 ± 1.0 mm (0.59 ± 0.04 inch)     |
6U-2191     | 511.025 ± 0.025 mm (20.119 ± 0.0010 inch)     |
266.36 ± 0.04 mm (10.487 ± 0.002 inch)     |
15.0 ± 1.0 mm (0.59 ± 0.04 inch)     |
2U-8155     | 511.025 ± 0.025 mm (20.1190 ± 0.0010 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
13.0 ± 0.5 mm (0.51 ± 0.02 inch)     |
2U-9800     | 511.025 ± 0.025 mm (20.1190 ± 0.0010 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
13.0 ± 0.5 mm (0.51 ± 0.02 inch)     |
2U-9801     | 511.025 ± 0.025 mm (20.1190 ± 0.0010 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
13.0 ± 0.5 mm (0.51 ± 0.02 inch)     |
7U-4353     | 511.025 ± 0.025 mm (20.1190 ± 0.0010 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
13.0 ± 0.5 mm (0.51 ± 0.02 inch)     |
2U-9700     | 511.025 ± 0.025 mm (20.1190 ± 0.0010 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
15.0 ± 1.0 mm (0.59 ± 0.04 inch)     |
105-8767     | 495.00 ± 0.250 mm (19.488 ± 0.0100 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
14.75 ± 0.25 mm (0.581 ± 0.010 inch)     |
142-0543     | 495.00 ± 0.250 mm (19.488 ± 0.0100 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
14.75 ± 0.25 mm (0.581 ± 0.010 inch)     |
142-0544     | 495.00 ± 0.250 mm (19.488 ± 0.0100 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
14.75 ± 0.25 mm (0.581 ± 0.010 inch)     |
170-2270     | 495.00 ± 0.250 mm (19.488 ± 0.0100 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
14.75 ± 0.25 mm (0.581 ± 0.010 inch)     |
121-9519     | 495.00 ± 0.250 mm (19.488 ± 0.0100 inch)     |
294.71 ± 0.04 mm (11.603 ± 0.001 inch)     |
14.75 ± 0.25 mm (0.581 ± 0.010 inch)     |
6U-3966     | 703.750 ± 0.250 mm (27.7066 ± 0.0100 inch)     |
399.93 ± 0.20 mm (15.745 ± 0.008 inch)     |
NA     |
138-1472     | 512.000 ± 0.250 mm (20.1574 ± 0.0100 inch)     |
270.00 ± 0.04 mm (10.630 ± 0.001 inch)     |
15.00 ± 0.25 mm (0.591 ± 0.010 inch)     |
190-2768     | 527.250 ± 0.250 mm (20.7578 ± 0.0100 inch)     |
295.00 ± 0.04 mm (11.614 ± 0.001 inch)     |
15.00 ± 0.25 mm (0.591 ± 0.010 inch)     |