Thermal Spray Procedures for Torque Converter Flange - Bearing Diameter {0679, 3101} Caterpillar


Thermal Spray Procedures for Torque Converter Flange - Bearing Diameter {0679, 3101}

Usage:

D6D 01Y
Pipelayer
All
Track-Type Tractor
All

Introduction

Table 1
Revision  Summary of Changes in SEBF9296 
03  Added 3 part numbers. 
02  Changed supplier name from Sulzer Metco to Oerlikon Metco. 
01  Added confidentiality statement, Think Safety graphic, and updated Praxair TAFA arc spray system. 

© 2016 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources 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 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 the procedure is safe for you and for other people to use. Ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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

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 2g03163360

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  Cast Iron 
Hardness  28-34 Rc 

Arc Spray Equipment and Procedure

Table 3
Maximum Surface Finish  1.52 Micrometer (60.000 Microinch) 
Reason for Spraying  Wear, grooving, or corrosion 
Mating Part Contact Area & Material  Bearing 
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 
Equipment Required  Turn (Horizontal or Vertical) 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  If desired   
Remove Oxide  Use emery cloth or glass bead blaster   
Clean Spray Area  Commercial degreaser   
Mask for Grit Blaster  Duct tape, metal shield, or rubber   
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  Duct Tape, metal shield, or rubber   
Metal Spray Equipment Type  Smart Arc by Oerlikon Metco  TAFA   
  Consumable (Bond coat)  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 (176 to 298 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  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



Illustration 3g03163385

Table 5
TTT and Pipelayers Torque Converter Output Flange-Bearing Diameters 
Part No.  Datum A  Bearing Diameter 
1T-0238  74.613 ± 0.018 mm (2.9375 ± 0.0010 inch)  110.010 ± 0.008 mm (4.3311 ± 0.0003 inch) 
1T-0254  65.088 ± 0.013 mm (2.5625 ± 0.0005 inch)  89.995 ± 0.008 mm (3.54310 ± 0.0003 inch) 
1T-0422  47.625 ± 0.013 mm (1.8750 ± 0.0005 inch)  65.011 ± 0.008 mm (2.5595 ± 0.0003 inch) 
1T-2087 
1T-1846 
1T-2072 
1T-1769  65.790 ± 0.050 mm (2.5902 ± 0.0020 inch)
7G-2953  79.228 ± 0.025 mm (3.1192 ± 0.0010 inch)  109.977 ± 0.01 mm (4.3298 ± 0.001 inch) 
7G-5270  74.613 ± 0.018 mm (2.9375 ± 0.0007 inch)  110.010 ± 0.008 mm (4.3311 ± 0.0003 inch) 
106-7097 
121-0023  79.228 ± 0.025 mm (3.1192 ± 0.0010 inch)  109.977 ± 0.01 mm (4.3298 ± 0.001 inch) 
207-5294  50.621 ± 0.025 mm (1.9930 ± 0.0010 inch)  70.010 ± 0.008 mm (2.7563 ± 0.0003 inch) 

1. Total indicator run-out (TIR) of the bearing diameter to datum A is 0.076 mm (0.0030 inch)

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