Thermal Spray Procedures for OHT Differential Carrier{0679, 3258, 3284} Caterpillar


Thermal Spray Procedures for OHT Differential Carrier{0679, 3258, 3284}

Usage:

769C 01X
Off-Highway Truck/Tractor: All

Introduction

Table 1
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 1g02139237

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.

------ WARNING! ------

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 2g03130899

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

Table 2
Base Metal     Ductile Iron    
Hardness        

Arc Spray Equipment and Procedure

Table 3
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    

Table 4
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

Table 5
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    

Table 6
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 3g03578896

Table 7
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    

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