- Off-Highway Truck/Tractor: All
Introduction
Revision     | Summary of Changes in SEBF2194     |
04     | Changed supplier name from Sulzer Metco to Oerlikon Metco.     |
03     | Added one part number.     |
02     | Added confidentiality statement, Think Safety graphic, and updated Praxair TAFA arc spray system.     |
01     | Changed Document Title     |
© 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:
- 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 in order 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 it 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 | g03130899 |
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     | Ductile Iron     |
Hardness     |     |
Arc Spray Equipment and Procedure
Maximum Surface Finish     | 3.5 Micrometer (140 Microinch)     |
Reason for Spraying     | Eliminate loose fit between carrier assembly and axle housing     |
Mating Part Contact Area & Material     | Axle housing     |
Arc Spray Equipment Type     | SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU     |
Wire     | TAFA 30T 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 or headstock/tailstock arrangement, rotary turntable     |
Rotation Speed     | 92.0 SMPM (300.00 SFPM)     |
Surface Preparation Method     | Undercut and Grit blast     |
Equipment Required     | Turn (Horizontal or Vertical) Lathe     |
Recommended Cutting Tool     | ISCAR DNMG 432TFIC507     |
Blast Media Recommendation     | Pressure Type Only (Aluminum Oxide Grit)     |
Remarks     | With a split bed lathe, a fixture must be used to support the carrier assembly     |
Arc Spray     | Procedure     | Check List     | ||
Clean Part     | Degrease in hot caustic solution     |     | ||
Undercut     | To "tru-up" surface     |     | ||
Chamfer     | If required - 1.0 mm (0.039 inch) x 45°     |
    | ||
Remove Oxide     | Use fiber flap brush or Clean/strip disc     |     | ||
Clean Spray Area     | Commercial degreaser     |     | ||
Mask for Grit Blaster     | Duct tape     |     | ||
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     | Make sure that surface is clean     |     | ||
Mask for Metal Spray     | AntiBond or Blue Layout Dye     |     | ||
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 30T     | TAFA 30T     |     |
    | Clamp Pressure     | 275 kPa (40 psi)     |
    |     |
    | Air Jets/Pressure     | 415 kPa (60 psi)     |
415 kPa (60 psi)     |
    |
    | Arc Load Volts     | 31V     | 31V     |     |
    | Amps     | 150 Amps     | 175 Amps     |     |
    | Gun to Work Distance (Standoff)     | 166 mm (6.5 inch)     |
166 mm (6.5 inch)     |
    |
    | Spray Rate/Build Up     | 0.058 mm (0.0023 inch)/pass     |
0.058 mm (0.0023 inch)/pass     |
    |
    | Rotation Speed of Part (RPM)     | RPM varies depending on diameter (23 to 48 RPM)     |     | |
    | 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     | Lathe     |     | ||
Part/Cutter Rotation     | Roughing 50.0 SMPM (150.00 SFPM) Finishing 75.0 SMPM (250.00 SFPM)     |
    | ||
Coolant     | Oil base synthetic - 40:1 ratio     |     | ||
Traverse Speed     | 0.30 mm (0.012 inch) per revolution     |
    | ||
Depth of Rough Cut     | 0.51 mm (0.020 inch) per side max.     |
    | ||
Depth of Finish Cut     | 0.25 mm (0.010 inch) per side max.     |
    |
Flame Spray Equipment and Procedure
Maximum Surface Finish     | 3.5 Micrometer (140 Microinch)     |
Reason for Spraying     | Eliminate loose fit between carrier assembly and axle housing     |
Mating Part Contact Area & Material     | Axle housing     |
Metco Equipment Type     | 6P-II by Oerlikon Metco     |
Metco Material     | Metco 453     |
Finish Thickness     | As Required     |
Finishing Allowance     | 0.51 to 0.64 mm (0.020 to 0.025 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     | Filtered Shop Air     |
Rotation/Traverse Device     | Lathe or headstock/tailstock arrangement, rotary turntable     |
Rotation/Traverse Speed     | 92.0 SMPM (300.00 SFPM)     |
Surface Preparation Method     | Undercut and Grit Blast     |
Finishing Method     | Machine     |
Machining Equipment Type     | Split-bed Lathe or Vertical Lathe     |
Recommended Cutter Grade     | C-2, 883 Carboloy, or equivalent     |
Remarks     | With a split bed lathe, a fixture must be used to support the carrier assembly     |
Flame Spray Process (6P-II)     | 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 Grit Blast     | Duct Tape     |     |
Grit Blast Equipment     | Pressure type only     |     |
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 (33 to 43 RPM)     |     |
Rotation Speed Of Part     | 92.0 SMPM (300.00 SFPM)     |
    |
Traverse Rate of Gun     | 15.00 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     | 92.0 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     |
    |
Specifications
Illustration 3 | g03578896 |
OHT Differential Carrier     | |||||
Part No.     | A     | B     | C     | D     | E     |
9M-3613     | 136.65 ± 0.20 mm (5.380 ± 0.008 inch)     |
25.40 ± 0.051 mm (1.000 ± 0.0020 inch)     |
609.50 ± 0.051 mm (23.996 ± 0.0020 inch)     |
15° ± 1°     | 3.0 ± 0.4 mm (0.12 ± 0.02 inch) C/R     |
2G-2655     | 145.36 ± 0.20 mm (5.723 ± 0.008 inch)     |
22.35 ± 0.051 mm (0.880 ± 0.0020 inch)     |
609.50 ± 0.051 mm (23.996 ± 0.0020 inch)     |
15° ± 1°     | 3.0 ± 0.4 mm (0.12 ± 0.02 inch) C/R     |
7D-2896     | 177.80 ± 0.051 mm (7.000 ± 0.0020 inch)     |
12.70 ± 0.051 mm (0.500 ± 0.0020 inch)     |
698.35 ± 0.051 mm (27.494 ± 0.0020 inch)     |
30° ± 1°     | 1.5 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
9D-5883     | 139.70 ± 0.051 mm (5.500 ± 0.0020 inch)     |
17.53 ± 0.051 mm (0.690 ± 0.0020 inch)     |
692.66 ± 0.051 mm (27.270 ± 0.0020 inch)     |
30° ± 1°     | 1.5 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
5T-8173     | 139.70 ± 0.051 mm (5.500 ± 0.0020 inch)     |
12.5 ± 0.5 mm (0.492 ± 0.02 inch)     |
698.35 mm ± 0.051 mm (27.494 ± 0.0020 inch)     |
30° ± 1°     | 1.5 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
225-6553     | 139.70 ± 0.051 mm (5.500 ± 0.0020 inch)     |
12.5 ± 0.5 mm (0.49 ± 0.02 inch)     |
698.35 ± 0.051 mm (27.494± 0.0020 inch)     |
30° ± 1°     | 1.5 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
104-9408     | 88.21 ± 0.051 mm (3.473 ± 0.0020 inch)     |
14.30 ± 0.051 mm (0.563 ± 0.0020 inch)     |
781.30 ± 0.051 mm (30.760 ± 0.0020 inch)     |
30° ± 1°     | 1.5 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
9D-0767     | 87.45 ± 0.051 mm (3.443 ± 0.0020 inch)     |
14.30 ± 0.051 mm (0.563 ± 0.0020 inch)     |
780.90 ± 0.051 mm (30.744 ± 0.0020 inch)     |
30° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
5T-8595     | 150.12 ± 0.051 mm (5.910 ± 0.0020 inch)     |
13.80 ± 0.25 mm (0.5433 ± 0.01 inch)     |
780.90 ± 0.051 mm (30.744 ± 0.0020 inch)     |
30° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
109-7184 125-6180 130-6631     |
150.12 ± 0.051 mm (5.910 ± 0.0020 inch)     |
13.80 ± 0.25 mm (0.543 ± 0.01 inch)     |
820.17 ± 0.051 mm (32.290 ± 0.0020 inch)     |
15° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
5T-5851     | 188.00 ± 0.051 mm (7.402 ± 0.0020 inch)     |
13.80 ± 0.25 mm (0.543 ± 0.01 inch)     |
855.00 ± 0.051 mm (33.661 ± 0.0020 inch)     |
30° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
8W-9426     | |||||
125-6041     | 188.00 ± 0.051 mm (7.402 ± 0.0020 inch)     |
13.80 ± 0.25 mm (0.543 ± 0.01 inch)     |
855.00 ± 0.051 mm (33.661 ± 0.0020 inch)     |
15° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
8X-0313     | 188.00 ± 0.051 mm (7.402 ± 0.0020 inch)     |
13.80 ± 0.25 mm (0.543 ± 0.01 inch)     |
1010.50 ± 0.051 mm (39.783 ± 0.0020 inch)     |
30° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
124-6019 134-7869     |
188.00 ± 0.051 mm (7.402 ± 0.0020 inch)     |
13.80 ± 0.25 mm (0.543 ± 0.01 inch)     |
1010.50 ± 0.051 mm (39.783 ± 0.0020 inch)     |
15° ± 1°     | 1.5 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
141-3141     | 50.00 ± 0.051 mm (1.969 ± 0.0020 inch)     |
31 ± 0.5 mm (1.220 ± 0.02 inch)     |
1300.25 ± 0.05 mm (51.190 ± 0.002 inch)     |
15° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |
293-5499     | 188.00 mm (7.402 inch)     |
13.8 ± 0.25 mm (0.5433 ± 0.01 inch)     |
1010.9 ± 0.05 mm (39.7991 ± 0.002 inch)     |
15° ± 1°     | 1.6 ± 0.4 mm (0.06 ± 0.02 inch) C/R     |