- Off-Highway Truck/Tractor: All
Introduction
Revision     | Summary of Changes in SEBF9295     |
02     | Corrected reference document listed in Specifications section.     |
01     | Changed supplier name from Sulzer Metco to Oerlikon Metco, added confidentiality statement, and Think Safety graphic.     |
00     | Information removed from SERF8705 (HVOF 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 Cat 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:
- Cat 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 specifically 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 | g03163256 |
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. You must 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. Cat dealers can supply the most current information.
Part Description
Base Metal     | Steel     |
Hardness     | 50-53 Rc     |
HVOF Spray Equipment and Procedure
Surface Finish     | Using a 5 micron stylus: Ra = 0.076 µm (3.000 µin) to 0.203 µm (8.000 µin) OR Rz = 0.70 µm (27.559 µin) Note: Either scale can be used to measure the surface finish, however, Ra and Rz do not equate to each other physically or mathematically as they measure different surface profiles. Only one of these measurements needs to be met.     |
Reason for Spraying     | Wear, grooving, or corrosion     |
Mating Part Contact Area & Material     | Bearing     |
Oerlikon Metco Equipment Type     | Diamond Jet Hybrid Spray System     |
Material     | WOKA 7103     |
Finish Thickness     | As Required     |
Finishing Allowance     | 0.025 mm (0.0010 inch) - 0.037 mm (0.0015 inch) per side     |
Spray Angle     | 90°     |
Spraying Not to Exceed     | 148° C (300° F)     |
Auxiliary Cooling     | Filtered shop air     |
Rotation/Traverse Device     | Lathe or headstock/tailstock arrangement     |
Rotation/Traverse Speed     | 45.7 SMPM (150.00 SFPM) (Traverse rate of 5.000 mm (0.1875 inch) per revolution)     |
Surface Preparation Method     | Strip chrome or HVOF coating and grit blast     |
Stripping Method     | 3MTM TrizactTM Diamond Cloth Belt or 3M Cubitron Cloth Belt Grinding     |
Recommended Equipment     | Finishers Tech Super G-6 Belt Grinder or equivalent or CNC Cylindrical Grinder     |
Recommended Abrasive     | HVOF Coating - 3MTM TrizactTM Diamond Cloth Belts 663FC (70 micron) Chrome Coating - 3MTM CubitronTM Cloth Belts 966F (24 Grit)     |
Machining Equipment Type     | Lathe with grinder attachment or Cylindrical Grinder     |
Blast Media Recommendations     | Pressure Type Only (20 Mesh Aluminum Oxide Grit) Blast Profile: 6.0 Micrometer (236.22 Microinch) profile minimum     |
Finishing and Superfinishing Equipment Type     | Diamond Belt Grinding and Superfinishing     |
Grinding Equipment     | Finishers Tech Super G-6 Grinder or equivalent or CNC Cylindrical Grinder     |
Recommended Abrasive     | 3MTM TrizactTM Diamond Cloth Belts 663FC (70 micron)     |
Superfinishing Equipment     | Supfina 210, IMPCO, GEM or equivalent     |
Recommended Abrasive     | 3MTM Diamond Microfinishing Film 675L (20 micron)     |
Method Replaced     | Scrap, new, or re-chrome     |
HVOF Spray Process (Hybrid Gun)     | Salvage Procedure     | Check List     | ||
Straighten Part     | Step 1     |     | ||
    | Equipment Necessary     | Eitel Straightening Press or Equivalent     |     | |
    | Maximum Runout Allowed     | 0.038 per 0.91 m (0.0015 per 36.000 inch)     |
    | |
Strip Chrome or HVOF Coating     | Step 2     |     | ||
    | Rotational and Positioner Equipment     | Lathe or CNC Cylindrical Grinder     |     | |
    | Grinding Equipment     | FT Super G-6 Belt Grinding Machine     |     | |
    | Contact Wheel     | Plain Face, Incompressible (Aluminum, steel or other), 6.4 mm (0.25 inch) wider than belt     |
    | |
    | Coolant     | Use flood coolant of water with 5% Synthetic coolant such as Milicron 46C or equivalent     |     | |
    | Contact Wheel vs. Rod Rotational Direction     | Opposing Directions (Rotate towards the contact area)     |     | |
    | Chrome Stripping Requirements     |     | ||
    | Abrasive     | 3MTM CubitronTM Cloth Belts 966F 24 grit     |     | |
    | Idler Force     | 70 - 100 lbs idler force per inch of belt width     |     | |
    | Belt Speed     | 1830.0 SMPM (6000.00 SFPM)     |
    | |
    | Spindle Speed     | 31.0 SMPM (100.00 SFPM)     |
    | |
    | Rotation Speed Of Part (RPM)     | RPM varies depending on diameter     |     | |
    | Traverse Speed     | 6.0 mm (0.25 inch) per revolution     |
    | |
    | HVOF Stripping Requirements     |     | ||
    | Abrasive     | 3MTM TrizactTM Diamond Cloth Belts 663FC (70 micron)     |     | |
    | Idler Force     | 70 - 100 lbs idler force per inch of belt width     |     | |
    | Belt Speed     | 1830.0 SMPM (6000.00 SFPM)     |
    | |
    | Spindle Speed     | 23.0 SMPM (75.00 SFPM)     |
    | |
    | Rotation Speed Of Part (RPM)     | RPM varies depending on diameter     |     | |
    | Traverse Speed     | 6.0 mm (0.25 inch) per revolution     |
    | |
    | Infeed Per Pass (inches on diameter)     | 0.060 mm (0.0025 inch)     |
    | |
Clean the Spray Area     | Step 3 Degrease in hot caustic solution or wipe with a degreasing agent     |
    | ||
Surface Preparation (Grit Blast)     | Step 4     |     | ||
    | Mask For Blast     | Duct Tape     |     | |
    | Blast Equipment     | Pressure Type Only     |     | |
    | Grit Type And Size     | 20 mesh Aluminum Oxide     |     | |
    | Heat Treated Rods Rotational Speed     | 61.0 SMPM (200.00 SFPM)     |
    | |
    | Non Heat Treated Rods Rotational Speed     | 122.0 SMPM (400.00 SFPM)     |
    | |
    | Traverse Rate of Blast Nozzle     | 5.000 mm (0.1875 inch) per revolution     |
    | |
    | Blast Air Pressure     | 689 kPa (100.0 psi)     |
    | |
    | Blast Nozzle to Work Piece Distance     | 51 mm (2.0 inch) - 127 mm (5.0 inch)     |
    | |
    | Recommended Blast Profile     | 6.0 Micrometer (236.22 Microinch) profile minimum     |
    | |
HVOF Coating     | Step 5     |     | ||
Refer to SEBF9236 for HVOF Spray Parameters     | ||||
HVOF Grinding and Superfinishing     | Step 6     |     | ||
    | Rotational and Positioner Equipment     | Lathe or CNC Cylindrical Grinder     |     | |
    | Coolant     | Use flood coolant of water with 5% Synthetic coolant such as Milicron 46C or equivalent.     |     | |
    | Contact Wheel vs. Rod Rotational Direction     | Opposing Directions (Rotate towards the contact area)     |     | |
    | HVOF Grinding Requirements     |     | ||
    | Grinding Equipment     | FT Super G-6 Belt Grinding Machine or equivalent     |     | |
    | Contact Wheel     | Plain face, Incompressible (Aluminum, steel or other), 6.4 mm (0.25 inch) wider than belt     |
    | |
    | Abrasive     | 3MTM TrizactTM Diamond Cloth Belts 663FC (70 micron)     |     | |
    | Belt Speed     | 1830.0 SMPM (6000.00 SFPM)     |
    | |
    | Idler Force     | 70 - 100 lbs idler force per inch of belt width     |     | |
    | Spindle Speed     | 23.0 SMPM (75.00 SFPM)     |
    | |
    | Rotation Speed Of Part (RPM)     | RPM varies depending on diameter     |     | |
    | Traverse Speed     | 6.0 mm (0.25 inch) per revolution     |
    | |
    | Infeed Per Pass (inches on diameter)     | 0.060 mm (0.0025 inch)     |
    | |
    | HVOF Superfinishing Requirements     |     | ||
    | Superfinishing Equipment     | Supfina 210, IMPCO, GEM or equivalent     |     | |
    | Contact Wheel     | Plain face, 60 Shore A hardness     |     | |
    | Abrasive - HVOF Superfinishing     | 3MTM Diamond Microfinishing Film 675L (20 micron)     |     | |
    | Contact Force     | 20-40 lbs     |     | |
    | Abrasive Feed Rate     | 8.4 mm (0.33 inch) per minute     |
    | |
    | Belt Oscillation (Machine Setting)     | Optional     |     | |
    | Spindle Speed     | 92.0 SMPM (300.00 SFPM)     |
    | |
    | Rotation Speed Of Part (RPM)     | RPM varies depending on diameter     |     | |
    | Traverse Speed     | 1.5 mm (0.06 inch) per revolution     |
    |
Note: Contact wheels are to be 6.0 mm (0.25 inch) wider than the belt to ensure that the belt width is supported evenly from edge-to-edge. Depth of cut for 3MTM TrizactTM Diamond Cloth Belts 663FC by grade (Depth of cut on the diameter per pass):
70 micron - 0.064 mm (0.0025 inch)
40 micron - 0.041 mm (0.0016 inch)
20 micron - 0.020 mm (0.0008 inch)
Belt Roll Grinding Recommended Operating Parameters     |
|||||
Abrasive     | 3MTM TrizactTM Diamond Cloth Belts 663FC     |     |     | ||
Contact Wheel     | Smooth Faced / Incompressible (Aluminum, 65 Shore D, Steel)     | ||||
Belt Width     | 2 inches*     | ||||
Belt Speed     | 6,000 SFPM     | ||||
End of Roll Dwell     | 1/2 Overlap - 2 Revolutions     | ||||
    | Shoulder Grind - 5 revolutions     | ||||
* Wider belt allows faster traverse | |||||
** Higher infeed traverse combinations have been achieved using cylindrical roll grinders | |||||
    | |||||
    | Chrome Carbide (CAT)     | ||||
=75 SFPM | =0.25 inch/rev.     | Grinding Infeeds     | |||
Rod Diameter     | RPM     | Traverse Rate     | Infeed Per Pass (on diameter)     | ||
(inches)     |
(Workpiece)     |
(inch/min)     |
663FC 70-micron     | 663FC 40-micron     | 663FC 20-micron     |
1.50     | 191.0     | 47.7     | 0.0025     | 0.0017     | 0.0008     |
2.00     | 143.2     | 35.8     | 0.0025     | 0.0017     | 0.0008     |
2.50     | 114.6     | 28.6     | 0.0025     | 0.0017     | 0.0008     |
3.00     | 95.5     | 23.9     | 0.0025     | 0.0017     | 0.0008     |
3.50     | 81.9     | 20.5     | 0.0025     | 0.0017     | 0.0008     |
4.00     | 71.6     | 17.9     | 0.0025     | 0.0017     | 0.0008     |
4.50     | 63.7     | 15.9     | 0.0025     | 0.0017     | 0.0008     |
5.00     | 57.3     | 14.3     | 0.0025     | 0.0017     | 0.0008     |
5.50     | 52.1     | 13.0     | 0.0025     | 0.0017     | 0.0008     |
6.00     | 47.7     | 11.9     | 0.0025     | 0.0017     | 0.0008     |
6.50     | 44.1     | 11.0     | 0.0025     | 0.0017     | 0.0008     |
7.00     | 40.9     | 10.2     | 0.0025     | 0.0017     | 0.0008     |
7.50     | 38.2     | 9.5     | 0.0025     | 0.0017     | 0.0008     |
8.00     | 35.8     | 9.0     | 0.0025     | 0.0017     | 0.0008     |
8.50     | 33.7     | 8.4     | 0.0025     | 0.0017     | 0.0008     |
9.00     | 31.8     | 8.0     | 0.0025     | 0.0017     | 0.0008     |
9.50     | 30.2     | 7.5     | 0.0025     | 0.0017     | 0.0008     |
10.00     | 28.6     | 7.2     | 0.0025     | 0.0017     | 0.0008     |
10.50     | 27.3     | 6.8     | 0.0025     | 0.0017     | 0.0008     |
11.00     | 26.0     | 6.5     | 0.0025     | 0.0017     | 0.0008     |
11.50     | 24.9     | 6.2     | 0.0025     | 0.0017     | 0.0008     |
12.00     | 23.9     | 6.0     | 0.0025     | 0.0017     | 0.0008     |
12.50     | 22.9     | 5.7     | 0.0025     | 0.0017     | 0.0008     |
13.00     | 22.0     | 5.5     | 0.0025     | 0.0017     | 0.0008     |
13.50     | 21.2     | 5.3     | 0.0025     | 0.0017     | 0.0008     |
14.00     | 20.5     | 5.1     | 0.0025     | 0.0017     | 0.0008     |
14.50     | 19.8     | 4.9     | 0.0025     | 0.0017     | 0.0008     |
15.00     | 19.1     | 4.8     | 0.0025     | 0.0017     | 0.0008     |
Superfinishing Chrome Carbide Recommended Operating Parameters     |
|||||
Abrasive     | 3MTM Diamond Microfinishing Film 675L (20 micron)     |     |     | ||
Film Feed Rate     | 0.33 inch/min     | ||||
Applied Force     | 25 lb/inch     | ||||
Oscillation     | Low (Low/None: final pass)     | ||||
Film Width     | 2 inch*     | ||||
# of Passes     | 1 - 2 passes with a 25 - 35 Ra input finish**     | ||||
Obtainable Finish     | Using a 5 micron stylus: Ra = 0.076 µm (3.000 µin) to 0.203 µm (8.000 µin) OR Rz = 0.70 µm (27.559 µin) Note: Either scale can be used to measure the surface finish, however, Ra and Rz do not equate to each other physically or mathematically as they measure different surface profiles. Only one of these measurements needs to be met.     |
||||
    | * Wider film allows faster traverse     | ||||
** Finish obtained with 3MTM 663FC 70 micron | |||||
    | |||||
=300 SFPM     | =0.0625 inch/rev.     | ||||
Rod Diameter     | RPM     | Traverse Rate     | |||
(inches)     | (Workpiece)     | (inch/min)     | |||
1.50     | 764.0     | 47.7     | |||
2.00     | 573.0     | 35.8     | |||
2.50     | 458.4     | 28.6     | |||
3.00     | 382.0     | 23.9     | |||
3.50     | 327.4     | 20.5     | |||
4.00     | 286.5     | 17.9     | |||
4.50     | 254.7     | 15.9     | |||
5.00     | 229.2     | 14.3     | |||
5.50     | 208.4     | 13.0     | |||
6.00     | 191.0     | 11.9     | |||
6.50     | 176.3     | 11.0     | |||
7.00     | 163.7     | 10.2     | |||
7.50     | 152.8     | 9.5     | |||
8.00     | 143.2     | 9.0     | |||
8.50     | 134.8     | 8.4     | |||
9.00     | 127.3     | 8.0     | |||
9.50     | 120.6     | 7.5     | |||
10.00     | 114.6     | 7.2     | |||
10.50     | 109.1     | 6.8     | |||
11.00     | 104.2     | 6.5     | |||
11.50     | 99.6     | 6.2     | |||
12.00     | 95.5     | 6.0     | |||
12.50     | 91.7     | 5.7     | |||
13.00     | 88.1     | 5.5     | |||
13.50     | 84.9     | 5.3     | |||
14.00     | 81.9     | 5.1     | |||
14.50     | 79.0     | 4.9     | |||
15.00     | 76.4     | 4.8     |
Note: For dimensional specifications refer to SEBF8194: Specifications for Rear Suspension Cylinder Components Used In Off-Highway Trucks.