Vane Type Hydraulic Pumps {5055} Caterpillar

Agricultural Tractor

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C-Series

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Challenger

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Forest Products

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Landfill Compactor

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Off-Highway Truck/Tractor

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Pipelayer

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Road Reclaimer/Soil Stabilizer

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Rock Feeder

RF300 (S/N: RF41-UP)

Rock Mover

RM900 (S/N: RF31-UP)

Skid Steer Loader

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Telehandler

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Track-Type Loader

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Track-Type Skidder

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Wheeled Excavator

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Introduction

Table 1

Revision	Summary of Changes in SEBF8080
25	Added new serial number prefixes
24	Added new serial number prefixes
23	Added new serial number prefixes
22	Added RM900 Rock Mover, and RM300 Rock Feeder to document effectivity.
21	Added new serial number prefixes.

© 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 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

Canceled Part Numbers and Replaced Part Numbers

This document may 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.

Summary

This guideline shows visual examples of worn hydraulic vane pump components that are used on various machines. This guideline shows illustrations of used vane type pump parts which may or may not be used again with or without salvage or reconditioning operations. "Use again" wear specifications for certain hydraulic cartridge components are included in this guideline. Five different series of cartridges are shown in the charts. The pump series can be identified by the cam ring diameter or identified by the L/min (liters per minute) or gpm (gallons per minute) rating stamped on the ring.

This guideline also gives special cautions and notes for guidelines when working on vane-type hydraulic pump components. Including information about how to remove dirt, oil, and rust from the components.

If the components meet the specifications given to this guideline, the components can be expected to give normal performance until the next overhaul. When the same part is used again in the same application. Do not install a part in which this guideline shows cannot be used again. If a part has wear or damage that is not shown in this guideline, do not use the part again.

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 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.

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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. The "WARNING" safety alert symbol is shown below.

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.

Safety

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

References

Table 2

Media Number	Title
NENG2500	"Dealer Service Tool Catalog"
PECJ0003	"Hand Tools and Shop Supplies"
SEBF9236	"Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components"
SEBF9238	"Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240	"Fundamentals of Flame Spray for Reconditioning Components."

Power Lapping Procedure

Power lapping can remove wear patterns and surface scratches, providing a "near new" surface flatness on parts. The power lapping machine can be used on a wide range of parts that require flat, smooth surfaces. Power lapping can produce lap flat surfaces within tolerances of one light band 0.00295 mm (0.000116 inch). Consistent surface finishes of 2 to 3 RMS with absolute uniformity are easily attained.

Lapping machines are easy to operate. However, some general guidelines must be followed.

1. Check the lapping plates periodically, preferably every morning before starting production, to ensure lap plate flatness.

2. Fill the slurry tank with a lapping vehicle. The vehicle is purchased premixed, and a lapping compound should be added to the vehicle at a rate of 62.5 mL per liter (8 oz. per gallon).

3. Run the machine without parts for 4 to 6 minutes allowing the compound to mix evenly in the vehicle.

4. Load the parts to be lapped inside the conditioning rings. The parts should be free to move about within the ring, and not packed so that the parts remain stationary.

5. Lapping times will vary according to the severity of the flaw that is to be removed. Minor scratches or warpage can usually be removed within 30 to 60 minutes.

6. Before inspecting the flatness of the lapped part:

   1. Remove the dull finish caused by the lapping compound.

   2. Wash the part thoroughly.

   3. Polish the lapped surface, using 600 grit emery paper on a 4/0 polishing stand, until the surface reflects light.

Touch Lapping Procedure

The touch lapping procedure is used on some parts to salvage that part. The touch lapping procedure will not give a part a "like new" surface or surface flatness. The procedure is used only to remove discoloration and small surface marks.

Use 4/0 emery polishing paper. Refer to Tool Catalog, PECJ0003, "Cat Hand Tools and Shop Supplies". Put the emery paper on a ground surface plate ( 7B-0337 Surface Plate) so the paper is smooth. Do not use any other surfaces.

Wash the part in a clean solvent. Let the part dry at room temperature. Put hydraulic oil on the part and then put the part in a clean container.

1. Wet the emery paper with a clean solvent made of a petroleum base.

2. Place the part on the emery paper with the surface to be "touch lapped" on the paper.

3. Move the part in a pattern like a number "8". More than ten complete number "8" patterns is not necessary.

4. Wash the part in a clean solvent. Let the part dry at room temperature.

5. Put hydraulic oil on the part, and then put the part into a clean container.

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NOTICE
When you handle or put pump and motor parts in storage, care must be taken to prevent damage to the machined surfaces.

Illustration 3	g02552199
Touch lapping procedure used on a piston slipper face

Testing For Flatness

Illustration 4	g02552240
Optical flat

Illustration 5	g02552242
Light band pattern

A monochromatic light source and an optical flat are required to determine flatness. Refer to Illustration 4.

Test for flatness by observing the light emitted from the monochromatic light head, reflecting from the surface being checked, up through the optical flat. A series of dark bands and light spaces will be projected. The dark bands are not light rays, but show where interference is produced by reflections from the test piece in the optical flat. Inspect the light bands for straightness. If the bands are straight and parallel, the surface is flat. If the bands are curved, the surface is not flat but may be flat enough for your particular needs. Refer to Illustration 5.

Cleaning Procedure

Wash all parts in a clean solvent that is made from petroleum before inspection. Wash each part separately. If several parts are washed together, there is a possibility that a machined surface can be damaged. Allow the part to dry at room temperature.

Pump Group

Nomenclature

Illustration 6	g01180557
(1) Bolts (4) (2) Cover (3) Screws (2) (4) Pin (5) Inlet plate housing (6) Seal packs (7) Flex plates (8) Rotors (9) Vanes (10) Inserts (11) Ring (12) Outlet plate housing (13) O-ring seals (14) Seal ring (15) Backup ring (16) Lock ring (17) Retaining ring (18) Bearing (19) Shaft (20) Key (21) Spacer washer (22) Primary seal (23) Secondary seal (24) Body

Cartridge Group

Illustration 7	g03364782
Part of vane type pump cartridge (1) Inlet plate housing (2) Seal packs (3) Flex plates (4) Rotor (5) Vanes (6) Inserts (7) Ring (8) Outlet plate housing

Cleaning

Wash the inlet plate housing and outlet plate housing using a clean solvent made from petroleum. A light rinse is sufficient.

Testing

Parts within pump cartridges work together to produce flow. The pump or motor efficiency depends on the amount of flow loss allowed by a grouping of individual parts. All rebuilt cartridges should be tested for efficiency to ensure acceptable performance.

Disassemble the Cartridge for Inspection

Proceed in the following order after the cartridge is removed from the housing.

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Illustration 8	g01179996

1. Scribe the cartridge to ensure correct positioning of all parts during assembly. Refer to Illustration 8.
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   Illustration 9	g01179998

2. Remove the inlet plate housing. Refer to Illustration 9.
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   Illustration 10	g01180014

3. Remove the inlet side flex plate. Refer to Illustration 10.
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   Illustration 11	g01180019

4. Turn the cartridge upside-down and use a piece of wood to hold the ring, the rotor, and the vanes in position.

5. Remove the outlet plate housing. Refer to Illustration 11.
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   Illustration 12	g01180020

6. Remove the outlet side flex plate. Refer to Illustration 12.
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   Illustration 13	g01180023

7. Remove the vanes in sequence, starting from the arrow on the rotor. Refer to Illustration 13.

Inlet and Outlet Plate Housings

Illustration 14	g01180027
Outlet plate housing. The arrow indicates the O-ring groove.

Illustration 15	g01180046
Cracked outlet plate Do not use again

Illustration 16	g01180047
Inlet plate housing. The arrow indicates the bushing bore.

Inspection

Illustration 17	g01180049
Measuring the bushing bore in outlet plate housing

Use a telescoping gauge and outside micrometer to measure the bushing bore diameter. Refer to Illustration 17.

Five different series of cartridges are shown in Table 3. The series can be identified by the cam ring diameter or by the L/min (liters per minute) or the gpm (gallons per minute) rating stamped on the ring.

Table 3

End Plate Bushing Bore Specifications
Series	Nominal Diameter	Maximum Allowable Worn Diameter
20V	N/A	N/A
25V	20.02 ± 0.013 mm (0.788 ± 0.0005 inch)	20.04 mm (0.789 inch)
30V	22.26 ± 0.013 mm (0.876 ± 0.0005 inch)	22.28 mm (0.877 inch)
35V	22.26 ± 0.013 mm (0.876 ± 0.0005 inch)	22.28 mm (0.877 inch)
45V	26.25 ± 0.013 mm (1.034 ± 0.0005 inch)	26.27 mm (1.034 inch)

Note: "N/A" means that the dimensions are not applicable.

Flex Plate

Illustration 18	g01180055
Typical example of a flex plate

Cleaning

Wash the flex plates with a clean solvent which is made from petroleum. A light rinse is sufficient. Be careful not to scratch the bronze face of the flex plates during cleaning. The removal of discoloration from the bronze face of the flex plates is not necessary.

Flex plates with carbon deposits can be reused after cleaning. Carbon deposits can be removed by using the 6V-6050 Ultrasonic Cleaner Gp. Cleaning should be followed by either touch or power lapping of the plate. Refer to the "Touch Lapping Procedure" section for lapping procedures.

Illustration 19	g03363319
Carbon deposit on bronze face

Use again after cleaning and lapping.

Illustration 20	g03363345

Use again

Discoloration on flexible side plates is a normal condition. Discoloration is a result of the close clearances maintained between the rotor and the flexible plates and indicated that the pump is operating correctly. Refer to Illustration 20.

Inspection

Illustration 21	g01180199
Checking flex plates for flatness

Salvage

A flex plate that is not reusable due to pitting or scoring can be salvaged. Removal of material from the bronze face of the plate is the way to salvage the plate. The plate can be reused after salvage if the plate meets the minimum thickness specifications in Table 4. Metal may be removed by power lapping, touch lapping, or grinding.

Grinding

The bronze face of flex plates can be ground to remove scratches and erosion. Grinding can be followed by lapping to produce a 0.50 µm (20 microinch) maximum surface finish. Flex plates must meet thickness specifications given in Table 4. Flatness must be less than 0.064 mm (0.0025 inch).

Table 4

Flex Plates
Series	Thickness
20V	3.15 mm (0.124 inch)
25V	4.42 mm (0.174 inch)
30V	4.42 mm (0.174 inch)
35V	4.67 mm (0.184 inch)
45V	6.81 mm (0.268 inch)

Illustration 22	g03363350
The bronze face has discoloration and a small amount of pitting

Use Again

Illustration 23	g03363362
Discoloration

Use Again

Illustration 24	g01180282
Erosion due to aeration or cavitation

Use Again after the salvage procedure is done.

Illustration 25	g03363364
Bronze face with heat checks

Do not use again

Illustration 26	g03363366
Flex plate erosion

Erosion indicates poor inlet conditions, cavitation, or aeration.

Do not use again

Illustration 27	g03363367
The bronze face has deep pits and scoring that can be felt with a fingernail.

Do not use again

Illustration 28	g03363375
Bronze face has visible scoring

Do no use again

Illustration 29	g01180327
Peeling bronze surface

Do not use again

Illustration 30	g01180330
Erosion due to aeration or cavitation. Pitting is too severe to salvage.

Do not use again

Illustration 31	g03363376
Dark color and erosion

The color and erosion indicated excessive system temperature. Replace the cartridge if this problem occurs. Refer to Illustration 31.

Do not use again

Illustration 32	g01180333

Notice the burnt oil residue on the plates. This residue indicates excessive system temperature. Replace the cartridge if this problem occurs.

Do not use again

Cam Ring

Illustration 33	g01180335
(A) Vane path (B) Pin hole

Cleaning

Wash the cam rings with a clean solvent made from petroleum. A light rinse is sufficient for cleaning.

Inspection

Illustration 34	g03363727
Shiny Surface due to normal wear

Illustration 35	g03363736
Small marks on the vane path

Use Again

After removing the burns with a 600 grit emery paper and light hydraulic oil.

Illustration 36	g03363737
Polishing lines on the vane path

Use Again

The surface finish and the contour of the vane path is critical to the cartridge life. Caterpillar does not recommend the resurfacing of cam ring vane paths. The contour of the vane path must follow a band established by a special master ring. The contour of the vane path must also follow the cam ring pin holes within tight tolerance limits. Surface finish requirements are also stringent and the requirements make resurfacing impractical.

All the vane pump cam rings will show signs of a shiny surface due to normal operation. Refer to Illustration 35. Mild ripples up to 0.05 mm (0.002 inch) deep can be polished for reuse. Refer to Illustrations 35 and 36.

Use Again

Table 5

Cam Ring
Series	GPM Rating(1)
20V	5 to 12	82.55 mm (3.250 inch)
25V	12 to 21	96.82 mm (3.810 inch)
30V	24	96.82 mm (3.810 inch)
35V	25 to 38	114.30 mm (4.500 inch)
45V	42 to 60	133.35 mm (5.250 inch)

(1)	The GPM rating is stamped on the cam ring.

Illustration 37	g03363743
Seizure accelerated by high temperatures in the cartridge

Do not use again

Illustration 38	g03363745

Do not use again

The notched cam ring and the erosion marks indicate poor inlet conditions are caused by cavitation or aeration.

Illustration 39	g03363749
Heat checks on the cam surface which indicates an aeration inlet.

Do no use again

Illustration 40	g01180360

Do not use again

Indications of contamination of the fluid in the system from cam ring frosting and ripple.

Illustration 41	g03363752

Do not use again

Indications of excessive system temperature from the cam ring discoloration and ripple.

Illustration 42	g03363757
Large mark on vane path

Do not use again

Illustration 43	g03363760
Cracked cam ring

Do not use again

Illustration 44	g01180367
Light chatter in vane path

Do not use again

Rotor

Illustration 45	g01180368
(C) Drive spline (D) Vane slot (E) Rotor face

Cleaning

Wash the rotor with clean solvent made from petroleum. A light rinse is sufficient.

Inspection

Check the vane slot wear and the rotor to ring clearance at assembly. The vane to slot clearance must be less than 0.03 mm (0.001 inch). The ring to rotor clearance is given in Table 6.

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Illustration 46	g01180370

1. Check the vane slot clearance with a feeler gauge. Refer to Illustration 46.
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   Illustration 47	g01180374

2. Set the 6V-7926 Dial Indicator Gp to zero on the rotor. Refer to Illustration 47.
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   Illustration 48	g01180377

3. Move the indicator to the ring and read the clearance. The allowable rotor clearances are given in Table 6.

Table 6

Ring to Rotor Clearances
Series	Maximum Clearance
20V	0.025 mm (0.001 inch)
25V	0.038 mm (0.0015 inch)
30V	0.033 mm (0.0013 inch)
35V	0.046 mm (0.0018 inch)
45V	0.048 mm (0.0019 inch)

Illustration 49	g03363768
Light scratches on a rotor face which cannot be felt with a fingernail

Use Again

The rotor can be salvaged by lapping if the correct ring to rotor clearance can be obtained. The ring to rotor clearance is given in Table 6.

Illustration 50	g03363773
Rotor smear indicates over pressure or low inlet pressure

Use Again after salvage.

Illustration 51	g03363777
Scratches on rotor face which can be felt with a fingernail

Do not use again

Vane and Vane Insert

Illustration 52	g01180391
(F) Vane tip (G) Vane end (H) Vane Insert

Cleaning

Wash the vanes and the vane inserts using a clean solvent made from petroleum. A light rinse is sufficient.

Inspection

Use a vernier caliper to measure the vane height. Minimum allowable heights after grinding are given in Table 7. The tip angle must be 20° ± 5° and the flat on the tip must be 0.28 mm (0.011 inch) to 0.43 mm (0.017 inch) wide.

Table 7

Vane Height
Series	Minimum
20V	13.67 mm (0.538 inch)
25V	15.57 mm (0.613 inch)
30V	15.57 mm (0.613 inch)
35V	17.60 mm (0.693 inch)
45V	21.97 mm (0.865 inch)

Illustration 53	g01180406

Comparison of a new vane tip on the right side with one vane tip subjected to aeration on the left. The vane in the center is showing wear from contamination.

Illustration 54	g01180408
Vane tip with acceptable wear

Use Again

Illustration 55	g03364253
Vane which is showing wear from contamination.

Use Again

If the vane to slot clearance is within tolerance, and scratches cannot be felt with a fingernail, the vane is acceptable to use again.

Illustration 56	g01180411

Illustration 57	g01180412

Appearance of a new vane on the left compared to the frosted appearance of a vane subjected to fluid contamination on the right. Note the worn edge of the vane on the right side. Refer to Illustration 57.

Illustration 58	g03364256
Appearance of galled vanes which is an indication of over pressure

Do not use again

Illustration 59	g01180415

The appearance of a new vane is shown on the left. The frosted appearance of a vane subject to fluid contamination shown on the right. Refer to Illustration 59.

Illustration 60	g03364258
Vane end with scratches which can be felt with a fingernail

Do not use again

Illustration 61	g03364262
Vane tip with excessive wear

Do not use again

Shaft

Illustration 62	g03364275
Worn drive splines

Wearing of the shaft splines is caused by lack of engine or transmission oil through the pump drive passages. Refer to Illustration 62.

Do no use again

Illustration 63	g03364276
Example of fretting

Fretting is caused by a lack of lubrication at the spline drive end of the pump shaft. Refer to Illustration 63.

Do not use again

Illustration 64	g01180424
Grooves in the seal area which can be felt with a fingernail (J) Shoulder radius

Use Again - After the seal area is salvaged according to the correct procedure. Refer to the "Procedure to Salvage Shaft Seal Area" section in this document.

Procedure to Salvage Shaft Seal Area

Grooves in the seal area which can be felt with a fingernail can be removed to make the part usable again. Refer to Illustration 64.

Note: Follow the metal spray manufacturer directions carefully in the application of metal spray to the shaft seal area.

The salvage procedure is as follows:

1. Measure the shaft outside diameter at the seal area and at the shoulder radius (J) if present. Make a note of each dimension.

2. Worn or damaged surfaces designated as salvageable by chrome plating can also be salvaged by a metal spray process. Metal spray is an acceptable method of restoring a surface to the original size. Each step in the procedure is critical in achieving the desired coating bond and the surface finish. See Reuse and Salvage Guideline, SEBF9236, "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components".

3. Grind the seal area to the diameter which was measured in Step 1 to ± 0.05 mm (0.002 inch). The surface finish must be 0.40 µm (16.00 microinch) to 0.80 µm (32.00 microinch) to be acceptable. The wheel radius must be the same or greater than the shoulder radius (J) as measured in Step 1.