Thermal Spray Procedures for OHT Rear Duo-Cone Seal Retainer and Spacer {0679, 4051, 4201, 4251, 4267} Caterpillar

Thermal Spray Procedures for OHT Rear Duo-Cone Seal Retainer and Spacer {0679, 4051, 4201, 4251, 4267}

Usage:

769C 01X

Mining Truck: 794 AC (S/N: HRT1-UP)
Off-Highway Truck/Tractor: All; 794 AC (S/N: MN51-UP; MT51-UP)

Introduction

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Table 1
Revision	Summary of Changes in SEBF9288
04	Revised Effectivity, Revised Tables 2,37, and boilerplate.
03	Changed supplier name from Sulzer Metco to Oerlikon Metco.
02	Corrected dimensions in Table 7 and added eight part numbers.
01	Added confidentiality statement, Think Safety graphic, and updated Praxair TAFA arc spray system.
00	Information removed from SERF8473 (Arc Spray Guide CD) and formatted for delivery in SIS.

© 2019 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System Website (SIS Web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

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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 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.

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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”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

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Illustration 2	g00008666

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, and 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.

Summary

This guideline provides the procedures necessary to return specific rear wheel Duo-Cone seal retainers to specifications with use of arc spray. Life will vary depending on application, load, lubrication, and environment.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part meets the specifications within this guideline and the part is intended for a similar application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to condemn a part from reuse.

References

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Table 2
References
Media Number	Publication Type & Title
Channel1	"Why Reuse and Salvage Parts"
Channel1	https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
PERJ1017	Special Publication "Dealer Service Tools Catalog"
SEBF9238	Fundamentals of Arc Spray for Reconditioning Components

Service Advisories, Service Letters, and Technical Service Bulletins

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NOTICE

The most recent Service Advisories, Service Letters, and Technical Service Bulletins that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Service Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired.

Tooling and Equipment

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NOTICE

Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

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Table 3
Required Tooling and Equipment
Part Number	Description	Designation
— ⁽¹⁾	Personal Protective Equipment (PPE)	Personal Protection
4S-9405	Caliper 304.8 mm (12.00 inch)	Profile Measurement
5P-3920	Tool Rule 304.8 mm (12.00 inch)	Measurement Checks
8H-8581	Feeler Gauge 0.038 - 0.635 mm (0.0015 - 0.0250 inch)	Thickness Measurement Checks
367-9109	Caliper (Digital) 0 -150 mm (0 - 6.0 inch)	Measurement Checks ⁽²⁾
385-4008	Tools (Micrometer) External (54 - 60 inch)	External Measurement Checks
385-9422	Tools (Micrometer) Internal (2 - 24 inch)	Internal Measurement Checks
386-3364	Tool (Ruler) 1,000.0 mm (39.37 inch)	Measurement Checks
423-4373	Caliper Digital 0 - 200 mm (0 - 8 inch)	Measurement Checks ⁽²⁾
431-4150	Micrometers External 0 - 25 mm (0 - 1 inch)	External Measurement Checks
473-8688 or 473-8689	Instrument Group Micrometer, Inside 2.00 - 12.00 inch	Internal Measurement Checks
473-8688 or 473-8689	Instrument Group Micrometer, Inside 50 - 300 mm	Internal Measurement Checks
473-8690	Instrument Group Micrometer, Outside 0.00 - 4.00 inch	External Measurement Checks
473-8691	Instrument Group Micrometer, Outside 2.00 - 6.00 inch	External Measurement Checks
473-8692	Instrument Group Micrometer, Outside - Digital 152.4 - 304.8 mm (6.00 - 12.00 inch)	External Measurement Checks
474-3709 or 474-3710	Instrument Group Micrometer, Inside (8.00 - 32.00 inch)	Internal Measurement Checks
474-3709 or 474-3710	Instrument Group Micrometer, Inside 200 - 800 mm	Internal Measurement Checks
385-8484	Tool (Level) 305 mm (12 inch)	Level
—	Straight Edge	Flatness/ Straightness Checks
6V-2010	Polishing Stone	Gear Polishing
1U-9918	Brush	General Cleaning
1U-5512	Abrasive Material (Roll)	General Cleaning
8T-7765	Surface Reconditioning Pad (180 Grit)	General Cleaning
162-5791	Towel	General Cleaning

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⁽¹⁾	Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
⁽²⁾	NOTE: Micrometers are the most accurate means of measurement. Sometimes it is acceptable to use a caliper.

Part Description

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Table 4
Base Metal	Steel Casting
Hardness	60 Rc

Arc Spray Equipment and Procedure

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Table 5
Maximum Surface Texture	3.5 µm (138 µinch)
Reason for Spraying	Wear or grooving
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	Turn (Horizontal or Vertical) Lathe
Recommended Cutting Tool	ISCAR DNMG 432TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)

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Table 6
Arc Spray		Procedure
Clean Part		Degrease in hot Aluminum safe cleaner
Undercut		To "tru-up" surface
Chamfer		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		Remove mask material, 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 90MXC	TAFA 90MXC
	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		Milling Machine
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)

Specifications

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Illustration 3	g03158498
OHT Duo-Cone Seal Retainer

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Table 7
OHT Duo-Cone Seal Retainer
Part Number	Dimension A	Dimension B
2G-5622 160-0714	43.79 ± 0.25 mm (1.724 ± 0.010 inch)	25.40 ± 0.25 mm (1.000 ± 0.010 inch)
3D-6164	38.10 ± 0.25 mm (1.500 ± 0.010 inch)	28.45 ± 0.25 mm (1.120 ± 0.010 inch)
5D-0896	38.10 ± 0.25 mm (1.500 ± 0.010 inch)	28.45 ± 0.51 mm (1.120 ± 0.020 inch)
5D-7912	57.15 ± 0.25 mm (2.250 ± 0.010 inch)	19.05 mm (0.750 inch)
5T-3116 106-6533 132-6350	94.50 ± 0.25 mm (3.720 ± 0.010 inch)	49.28 ± 0.25 mm (1.940 ± 0.010 inch)
5T-5888 106-6536 107-8487 116-5241 137-1076	65.00 ± 0.25 mm (2.559 ± 0.010 inch)	31.80 ± 0.25 mm (1.252 ± 0.010 inch)
6D-0437	54.89 ± 0.13 mm (2.161 ± 0.005 inch)	31.75 ± 0.13 mm (1.250 ± 0.005 inch)
6G-6479 106-6535 107-8543 125-7924	64.86 ± 0.25 mm (2.554 ± 0.010 inch)	51.94 ± 0.25 mm (2.045 ± 0.010 inch)
7D-2889	39.60 ± 0.25 mm (1.559 ± 0.010 inch)	21.18 ± 0.25 mm (0.834 ± 0.010 inch)
8X-1202 106-6537 107-8485 118-8395	63.00 ± 0.25 mm (2.480 ± 0.010 inch)	46.6 ± 0.25 mm (1.834 ± 0.00 inch)
9D-9716 106-6534 107-8542	52.60 ± 0.25 mm (2.071 ± 0.010 inch)	38.10 ± 0.25 mm (1.500 ± 0.010 inch)
9M-3819	48.54 ± 0.13 mm (1.911 ± 0.005 inch)	25.40 ± 0.13 mm (1.000 ± 0.005 inch)
129-0377	84.81 mm (3.34 inch)	38.10 ± 0.25 mm (1.500 ± 0.010 inch)
132-6349	55.31 ± 0.25 mm (2.178 ± 0.010 inch)	38.10 ± 0.25 mm (1.500 ± 0.010 inch)
137-1077	77.30 ± 0.25 mm (3.043 ± 0.010 inch)	63.00 ± 0.25 mm (2.480 ± 0.010 inch)
142-5639	44.00 ± 0.25 mm (1.732 ± 0.010 inch)	33.62 ± 0.25 mm (1.324 ± 0.010 inch)
157-3906	60.32 ± 0.25 mm (2.375 ± 0.010 inch)	50.80 ± 0.25 mm (2.000 ± 0.010 inch)
183-9183 371-8453	128.60 ± 0.25 mm (5.063 ± 0.010 inch)	70.00 ± 0.25 mm (2.756 ± 0.010 inch)
190-6096	98.10 ± 0.13 mm (3.862 ± 0.005 inch)	42.00 ± 0.25 mm (1.654 ± 0.010 inch)
258-7603	66.60 ± 0.25 mm (2.622 ± 0.010 inch)	38.10 ± 0.13 mm (1.500 ± 0.005 inch)
260-6828	77.58 ± 0.25 mm (3.054 ± 0.010 inch)	49.28 ± 0.13 mm (1.940 ± 0.005 inch)
371-8453	108.6± 0.5 mm (4.28± 0.02 inch)	78.6± 0.5 mm (3.09± 0.02 inch)
375-5962	77.30 ± 0.25 mm (3.043 ± 0.010 inch)	63.00 ± 0.25 mm (2.480 ± 0.010 inch)