Thermal Spray Procedures for Torque Converter Carrier - Bearing Diameter {0679, 3101, 3135} Caterpillar


Thermal Spray Procedures for Torque Converter Carrier - Bearing Diameter {0679, 3101, 3135}

Usage:

D9H 12U
Pipelayer
571A (S/N: 64A1-UP)
572G (S/N: 8PC1-UP; 40U1-UP)
583H (S/N: 61A1-UP)
583K (S/N: 78V1-534)
583R (S/N: 2XS1-UP)
594H (S/N: 96V1-UP)
Track-Type Tractor
D6D (S/N: 31X1-UP)
D6G Series 2 (S/N: 2MJ1-UP)
D6H (S/N: 4RC1-UP; 6FC1-UP; 3ZF1-UP; 3YG1-UP)
D6H Series II (S/N: 8ZJ1-UP; 9KJ1-UP; 5KK1-UP; 6CK1-UP)
D6N (S/N: MG51-UP; GB61-UP; P5S1-UP; P5W1-UP)
D6R2 (S/N: PPP1-UP; SSS1-UP; TTT1-UP)
D7G Series 2 (S/N: 65V1-UP; 92V1-UP)
D7H (S/N: 80Z1-UP)
D8H (S/N: 46A1-UP)
D8K (S/N: 77V1-UP)
D8R (S/N: 7XM1-UP; 9EM1-UP)
D9G (S/N: 66A1-UP)
D9H (S/N: 12U1-UP; 90V1-UP; 97V1-UP; 98V1-UP; 99V1-UP)

Introduction

Table 1
Revision  Summary of Changes in SEBF2109 
02  Added 1 part number.
Updated copyright date to 2018. 
01  Added 2 part numbers. 
00  Information removed from SERF8704 (Flame Spray Guide CD) and formatted for delivery in SIS. 

© 2018 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 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 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 2g00008666

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.

For further information on the equipment needed to perform thermal spray processes, refer to the following publications:

Table 2
References 
  Title 
SEBF9236  Special Instruction , "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components" 
SEBF9238  Special Instruction , "Fundamentals of Arc Spray for Reconditioning Components" 
SEBF9240  Special Instruction , "Fundamentals of Flame Spray for Reconditioning Components" 

Part Description

Table 3
Base Metal  Gray Iron Casting 
Hardness 

Flame Spray Equipment and Procedure

Table 4
Maximum Surface Finish  1.6 Micrometers (63.00 Microinches) 
Reason for Spraying  Wear 
Mating Part Contact Area & Material  Bearing 
Metco Equipment Type  Metco 6P-II 
Metco Material  Metco 453 
Finish Thickness  As Required 
Finishing Allowance  0.51 mm (0.020 inch) to 0.64 mm (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  If desired 
Rotation/Traverse Device  Lathe or Rotary Table 
Rotation/Traverse Speed  91.4 SMPM (300.00 SFPM) 
Surface Preparation Method  Grit blast 
Finishing Method  Machine 
Machining Equipment Type  Lathe 
Recommended Cutter Grade  C-2, 883 Carboloy or equivalent 
Remarks  Refer to Form Special Instruction, SEBF8007, "Salvage Procedures For Worn Carriers Used in Torque Converters - 1T-0630, 1T-0611, and 1T-0670 on D8 and D9 Tractors" 

Table 5
Flame Spray Process (6P)  Procedure  Check List 
Clean Part  De-grease in hot caustic solution   
Undercut  To "tru-up" surface   
Chamfer  All edges - 45° x 0.76 mm (0.030 inch)   
Remove Oxide  Use fiber flap brush, Clean/strip disc   
Clean Spray Area  Metco cleaning solvent or equivalent   
Mask for Blast  Duct tape   
Blast Equipment  Pressure type only   
Grit Type and Size  METCOLITE C - Aluminum oxide   
Blast Air Pressure  620 kPa (90.0 psi)   
Blast Nozzle to Work Distance  50 mm (2.0 inch)   
Mask for Spray  Anti-bond or blue layout dye   
Spray Equipment Type  6P-II Hand Held Thermo Spray System   
Auxiliary Cooling  If desired   
Nozzle  6P-C7A-K "K" Nozzle   
Air Capacity/Pressure  6P-3/Cooling air 140 kPa (20.0 psi) - 170 kPa (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 (12.13 lb) per hour or 90 gr (3.2 oz) per min   
Gun to Work Distance  178 mm (7.0 inch)   
Rotation Speed of Part (RPM)  RPM varies depending on diameter (240 to 305 RPM)   
Rotation Speed of Part  91.4 SMPM (300.000 SFPM)   
Traverse Rate of Gun  15.24 SMPM (50.000 SFPM)   
Gun Fixturing Method  Machine mount or hand held   
Top Coat/Thickness  0.10 mm (0.004 inch) to 0.15 mm (0.006 inch) per pass   
Finishing Equipment  Lathe   
Part/Cutter Rotation  91.4 SMPM (300.000 SFPM)   
Traverse Speed  0.05 mm (0.002 inch) to 0.10 mm (0.004 inch) per revolution   
Depth of Rough Cut  0.38 mm (0.015 inch) to 0.51 mm (0.020 inch) per side   
Depth of Finish Cut  0.025 mm (0.010 inch) to 0.038 mm (0.015 inch) per side   
Additional Finish Method  Emery cloth for desired finish   

Specifications



Illustration 3g02996936


Illustration 4g02996937

Table 6
Part No.  Diameter (A) mm
(in.) 
Diameter (B) mm
(in.) 
Diameter (C) mm
(in.) 
1T-0213  120.010 ± 0.013 mm (4.7248 ± 0.0005 inch)  82.575 ± 0.025 mm (3.2510 ± 0.001 inch)  184.137 ± 0.013 mm (7.2495 ± 0.0005 inch) 
1T-0595  117.539 ± 0.013 mm (4.6275 ± 0.0005 inch)  82.575 ± 0.025 mm (3.2510 ± 0.001 inch)  184.137 ± 0.013 mm (7.2495 ± 0.0005 inch) 
1T-0226  120.010 ± 0.013 mm (4.7248 ± 0.0005 inch)  82.575 ± 0.025 mm (3.2510 ± 0.001 inch)  184.137 ± 0.013 mm (7.2495 ± 0.0005 inch) 
1T-0444  95.026 ± 0.013 mm (3.7412 ± 0.0005 inch)  92.862 ± 0.038 mm (3.6560 ± 0.0015 inch)  175.349 ± 0.013 mm (6.9035 ± 0.0005 inch) 
1T-1791  95.026 ± 0.013 mm (3.7412 ± 0.0005 inch)  92.860 ± 0.130 mm (3.6559 ± 0.005 inch)  175.349 ± 0.013 mm (6.9035 ± 0.0005 inch) 
1T-2047  95.016 ± 0.013 mm (3.7408 ± 0.0005 inch)  100.012 ± 0.025 mm (3.9375 ± 0.001 inch)  175.349 ± 0.013 mm (6.9035 ± 0.0005 inch) 
1T-2049  95.016 ± 0.013 mm (3.7408 ± 0.0005 inch)  100.012 ± 0.025 mm (3.9375 ± 0.001 inch)  175.349 ± 0.013 mm (6.9035 ± 0.0005 inch) 
129-1261  80 ± 0.5 mm (3.14960 ± 0.0196 inch)  60.375 ± 0.05 mm (2.37696 ± 0.0019 inch)  185.94 ± 0.02 mm (7.3204 ± 0.0008 inch) 
169-4740  69.0 ± 0.5 mm (2.72 ± 0.02 inch)  N/A  127.750 ± 0.013 mm (5.0295 ± 0.0005 inch) 
336-2434  94.87 ± 0.13 mm (3.7350 ± 0.005 inch)  70.0 ± 0.5 mm (2.756 ± 0.02 inch)  175.349 ± 0.02 mm (6.9035 ± 0.0008 inch) 
439-5274  89.997 ± 0.01 mm (3.5431 ± 0.0004 inch)  90.025 ± 0.025 mm (3.5443 ± 0.001 inch)  185.94 ± 0.02 mm (7.320 ± 0.0008 inch) 

Notes:

  1. Total indicator run-out (TIR) of the Diameter A to Diameter B is 0.05 mm (0.002 inch).

  2. Total indicator run-out (TIR) of the Diameter A to Diameter C is 0.05 mm (0.002 inch)

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