Thermal Spray Procedures for OHT Rear Strut - Head / Flange End{0374, 0599, 0679, 7201, 7213} Caterpillar


Thermal Spray Procedures for OHT Rear Strut - Head / Flange End{0374, 0599, 0679, 7201, 7213}

Usage:

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

Introduction

Table 1
Revision     Summary of Changes in SEBF9294    
03     Corrected reference document listed in Specifications section.    
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 formatted for delivery in SIS.    

© 2015 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. You should 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 2g03163097

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. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must 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     Steel casting or forging    
Hardness     23-32 Rc    

Arc Spray Equipment and Procedure

Table 3
Maximum Surface Finish     1.6 Micrometer (62.99 Microinch)    
Reason for Spraying     Wear or grooving    
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    
Rotation Speed    
92.0 SMPM (300.00 SFPM)    
Surface Preparation Method     Undercut and Grit blast if necessary    
Equipment Required     Horizontal Lathe    
Recommended Cutting Tool     ISCAR DNMG 432TFIC507    
Blast Media Recommendation     Pressure Type Only (Aluminum Oxide Grit)    

Table 4
Arc Spray     Procedure     Check List    
Clean Part     Degrease in hot caustic solution        
Undercut     To "tru-up" surface        
Chamfer     If required -
1.00 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 mm (2.0 in) to
150 mm (6.0 in)    
   
Remove Blast Mask     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    
0.015 mm (0.0006 inch)/pass    

0.015 mm (0.0006 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     32V        
    Amps     150 Amps     150 Amps        
    Gun to Work Distance (Standoff)    
166 mm (6.5 inch)    

102 mm (4.0 inch)    
   
    Spray Rate/Build Up    
0.058 mm (0.0023 inch)/pass    

0.015 mm (0.0006 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 on hand held        
Finishing Equipment     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)    
   

Specifications

Note: For dimensional specifications refer to SEBF8194: Specifications for Rear Suspension Cylinder Components Used In Off-Highway Trucks.

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