- Agricultural Tractor
- All
- Articulated Truck
- All
- Backhoe Loader
- All
- Compact Wheel Loader
- All
- Integrated Toolcarrier
- All
- Landfill Compactor
- 816K (S/N: LT61-UP; SLL1-UP)
- 826K (S/N: 2L31-UP; 2T61-UP)
- 836K (S/N: T6X1-UP; L6Z1-UP)
- 826K (S/N: 2L31-UP; 2T61-UP)
- Motor Grader
- All
- Off-Highway Truck/Tractor
- 69D (S/N: 9SS1-UP; 9XS1-UP)
- 73D (S/N: 9YS1-UP; 1GW1-UP)
- 768B (S/N: 79S1-UP)
- 768C (S/N: 02X1-UP)
- 769 (S/N: 99F1-UP; 35W1-UP)
- 769C (S/N: 01X1-UP)
- 769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
- 770 (S/N: JND1-UP; M7W1-UP; BZZ1-UP)
- 770G (S/N: KD21-UP; RMA1-UP; TWA1-UP; RMD1-UP; KDH1-UP; ECM1-UP; ECX1-UP)
- 772 (S/N: RLB1-UP; RGK1-UP; J2M1-UP; 10S1-UP; 11S1-UP; 80S1-UP)
- 772B (S/N: 64W1-UP)
- 772D (S/N: 5HR1-UP)
- 772G (S/N: KE31-UP; TWB1-UP; RME1-UP; RMH1-UP; LTS1-UP; KEX1-UP; LTX1-UP)
- 773 (S/N: 63G1-UP)
- 773B (S/N: 5SC1-UP; 63W1-UP)
- 773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP; 7FZ1-UP)
- 773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)
- 773F (S/N: EED1-UP; EXD1-UP)
- 773GC (S/N: RJZ1-UP)
- 776 (S/N: 14H1-UP; 14W1-UP)
- 776B (S/N: 6JC1-UP)
- 776C (S/N: 2TK1-UP)
- 776D (S/N: 5ER1-UP; AFS1-UP)
- 777 (S/N: 84A1-UP)
- 777B (S/N: 4YC1-UP; 3NF1-UP)
- 777C (S/N: 4XJ1-UP)
- 777D (S/N: DCB1-UP; AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP; 6XZ1-UP)
- 777E (S/N: KDP1-UP; KDZ1-UP)
- 777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)
- 777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)
- 779 (S/N: 45H1-UP)
- 783B (S/N: 8YM1-UP)
- 784B (S/N: 5RK1-UP)
- 784C (S/N: 2PZ1-UP)
- 785 (S/N: 8GB1-UP)
- 785B (S/N: 6HK1-UP)
- 785C (S/N: AP21-UP; 1HW1-UP; APX1-UP; 5AZ1-UP)
- 785D (S/N: DMC1-UP; MSY1-UP)
- 785G (S/N: SH21-UP; MS41-UP; TRG1-UP; RTL1-UP; WHS1-UP)
- 786 (S/N: 01A1-UP; 80A1-UP; 81A1-UP)
- 787B (S/N: 9TM1-UP)
- 789 (S/N: 9ZC1-UP)
- 789B (S/N: 7EK1-UP)
- 789C (S/N: 2BW1-UP)
- 789D (S/N: SP21-UP; SPD1-UP; SHH1-UP; TWP1-UP)
- 789G (S/N: TR21-UP)
- 793 (S/N: 3SJ1-UP)
- 793B (S/N: 1HL1-UP)
- 793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
- 793D (S/N: FDB1-UP)
- 793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)
- 796 (S/N: HRP1-UP; HRY1-UP)
- 797 (S/N: 5YW1-UP)
- 797B (S/N: JSM1-UP)
- 797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)
- 798 (S/N: ST71-UP)
- 73D (S/N: 9YS1-UP; 1GW1-UP)
- Paving Compactor
- All
- Pipelayer
- All
- Quarry Truck
- 771C (S/N: 3BJ1-UP)
- 771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
- 773G (S/N: G731-UP; G771-UP; MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)
- 775B (S/N: 7XJ1-UP)
- 775D (S/N: 6KR1-UP; 8AS1-UP)
- 775E (S/N: BEC1-UP)
- 775F (S/N: EYG1-UP; DLS1-UP)
- 775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)
- 771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
- Road Reclaimer/Soil Stabilizer
- All
- Soil Compactor
- 815K (S/N: SL91-UP; T1Y1-UP)
- 825K (S/N: 2L91-UP; 2T91-UP)
- Telehandler
- All
- Track-Type Loader
- All
- Track-Type Skidder
- All
- Track-Type Tractor
- All
- Underground Articulated Truck
- All
- Wheel Dozer
- All
- Wheel Loader
- All
- Wheel Skidder
- All
- Wheel Tractor-Scraper
- All
Introduction
Revision | Summary of Changes in SEBF8048 |
---|---|
21 | Added new serial number prefixes for New Product Introduction (NPI).
Tables arranged in alpha numeric sequence. Table 6 divided in to 8 tables. Each table is now with the corresponding illustration. Added Illustration 34 to the "Metal Spray Method to Repair Seal Surfaces" section. Added 8 part numbers. The 110-2141 Yoke dimension "B" has been updated with the correct dimension. |
20 | Added new serial number prefixes for New Product Introduction (NPI).
Added 4 part numbers. Added content from SEBF2152, "Thermal Spray Procedures for Transmission and Torque Converter Yokes". |
19 | Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018. |
18 | Added 4 part numbers. |
17 | Added 16 part numbers. |
© 2019 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 include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System Website (SIS web) 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 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.
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”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.
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.
Summary
This guideline provides the procedures necessary to determine the reusability of the (insert component name). Life will vary depending on application, load, lubrication, and environment.
This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part meets the specifications within this guideline and the part is intended for a similar application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.
The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to condemn a part from reuse. Follow visual inspections and the "Crack Detection Methods" section for further guidance.
Note: Illustrations in this guideline may appear different from some of the components. While the illustrations are typical, the dimensions are actual. All the dimensions that are listed are dimensions for manufacturing and assembling a new machine.
References
References | |
---|---|
Media Number | Publication Type & Title |
Channel1 | "Why Reuse and Salvage Parts" |
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z | |
PERJ1017 | Special Publication"Dealer Service Tools Catalog" |
SEBF8187 | Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures" |
SEBF9236 | Reuse and Salvage Guidelines
"Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for reconditioning Components" (1) |
SEBF9238 | Reuse and Salvage Guidelines
"Fundamentals of Arc Spray for reconditioning Components" (1) |
SEBF9240 | Reuse and Salvage Guidelines
"Fundamentals of Flame Spray for Reconditioning Components" (1) |
(1) | Only Cat dealers may utilize applications for Thermal Spray. The processes must be carried out within the facilities of the dealership. The dealership must maintain a clean environment and always use the correct equipment for all processes in each Thermal Spray Application. |
Service Advisories, Service Letters, and Technical Service Bulletins
NOTICE |
---|
The most recent Service Advisories, Service Letters, and Technical Service Bulletins that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Service Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired. |
Tooling and Equipment
NOTICE |
---|
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.
Required Tooling and Equipment | ||
---|---|---|
Part Number | Description | Designation |
— (1) | Personal Protective Equipment (PPE) | Personal Protection |
Plastic Hammer Assembly | General Tooling | |
Telescoping Magnet | General Tooling | |
Automatic Tape Measure (1-inch X 26- ft)
|
Measurement
Checks |
|
Caliper
|
Profile
Measurement |
|
Tool
Rule |
Measurement
Checks |
|
Feeler Gauge
|
Thickness
Measurement Checks |
|
Tools (Micrometer)
Internal |
Internal
Measurement Checks |
|
Tool (Ruler)
|
Measurement
Checks |
|
Micrometers
External |
External
Measurement Checks |
|
or |
Instrument Group
Micrometer, Inside 2.00 - 12.00 inch |
Internal
Measurement Checks |
Instrument Group
Micrometer, Inside 50 - 300 mm |
||
Instrument Group
Micrometer, Outside 0.00 - 4.00 inch |
External
Measurement Checks |
|
Instrument Group
Micrometer, Outside 2.00 - 6.00 inch |
External
Measurement Checks |
|
Instrument Group
Micrometer, Outside - Digital |
External
Measurement Checks |
|
or |
Instrument Group
Micrometer, Inside |
Internal
Measurement Checks |
Instrument Group
Micrometer, Inside |
||
—
and /or — |
GO/NO-GO Thread Gauge Set, Metric | Threaded Hole
Inspection |
GO/NO-GO Thread Gauge Set, SAE | ||
—(1) | Plastic Plug Assortment | Threaded Hole
Protection |
— (1) | Tap and Die Set | Threaded Hole
/ Restore |
Disc (Coarse) | Surface
Preparation / De-burring |
|
Threaded Shaft | Surface
Preparation / De-burring |
|
Holder (Disc Pad) | Surface
Preparation / De-burring |
|
Wheel
(60 Grit) |
Surface
Preparation / De-burring |
|
Grinding Wheel (F-Grade)
(120 Grit) |
Surface
Preparation / De-burring |
|
Wheel Adapter | Surface
Preparation / De-burring |
|
Die Grinder
(Right Angle) |
Surface
Preparation / De-burring |
|
Brush
|
Surface
Preparation / De-burring |
|
Metal Marking Pen | Parts Marking | |
Brush | General Cleaning | |
Surface Reconditioning Pad (180 Grit) | General Cleaning | |
Towel | General Cleaning | |
— | Paint Primer | Sleeve Installation |
Diagonal Cutter | Sleeve Installation | |
— | Compound (Retaining) | Sleeve Installation |
Pliers | Sleeve Installation | |
Tool Group
Dial Indicator |
Run-Out Checks | |
Universal Attachment (90°) | Total Indicator Reading (TIR) checks | |
Indicator Contact Point | Total Indicator Reading (TIR) checks | |
Comparison Gauge (Surface Texture) | Surface Texture
Tester |
|
Tool
Specimen |
Surface Texture
Tester |
|
Indicator
(Profilometer) |
Surface Texture
Tester |
|
Seal Pick
Kit |
Gear/ Shaft
Step Inspection |
|
Magnifying Glass | Visual Surface
Inspection (VT) |
|
Mirror (Telescoping) | Visual Surface
Inspection (VT) |
|
Flashing Lights Conversion Kit | Visual Surface
Inspection (VT) |
|
Light | Visual Surface
Inspection (VT) |
|
— (1) | Bright Incandescent Light | Visual Surface
Inspection (VT) |
— | Reflective Surface for Inspection | Visual Surface
Inspection (VT) |
Microscope (40-Power)
|
Crack/
Measurement Inspection |
|
Paper Towel | Liquid Penetrant
Testing (PT) |
|
Brush
Curved Handle Wire |
General Cleaning/
Liquid Penetrant Testing (PT) |
|
— | Developer | Liquid Penetrant
Testing (PT) |
— | Penetrating Oil | Liquid Penetrant
Testing (PT) |
— | Solvent Cleaner | General Cleaning/
Liquid Penetrant Testing (PT) |
Crack Detection Kit (Magnetic Particle) | Dry Magnetic
Particle Testing (MPT) |
|
— | Paint Pen | Dry Magnetic
Particle Testing (MPT) |
Lamp Group
Ultraviolet |
Wet Magnetic
Particle Testing (MPT) |
(1) | Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards. |
(2) | Available in the United States only. |
Prepare the Area for Inspection
Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using. |
Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than |
Illustration 3 | g03794147 |
Typical burr removal Tooling. (A) Die Grinder, Right Angle (B) Wheel Grinder, Group (C) Conditioning Discs, Disc pad Holder, and Threaded Shaft (D) Flapper Wheel |
- Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and oil.
- When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all lifting devices must be inspected before use.
- During cleaning, do not damage machined surfaces.
- Use pressurized air to dry parts.
- If component cannot be inspected immediately after cleaning, put hydraulic oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.
- Use appropriate thread taps to chase all threaded holes.
Standardized Parts Marking Procedure
Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".
The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.
Ensure that the mark is not covered by a mating part.
NOTICE |
---|
Do not use numbering stamp punches to mark internal components. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure. |
Illustration 4 | g06124077 |
DO NOT use numbering stamp punches to mark internal components. |
The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.
Example 1
Illustration 5 | g03856853 |
Typical Example |
Illustration 5 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.
Example 2
Illustration 6 | g03856857 |
Typical Example |
Illustration 6 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.
Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 6. In this example, the gear has a total of 22,000 hours.
Example 3
Illustration 7 | g03519882 |
Typical Example |
(A) Mark the planet pin on either end.
Parts Reusability
Illustration 8 | g02319654 |
Yoke face (1) Fretting (2) Slot |
Illustration 9 | g02319655 |
Yoke face (close view) (1) Fretting |
Transmission and differential yokes can be damaged by the fretting of the yoke face during normal operation. Illustration 8 and Illustration 9 show typical examples of fretting.
After machining the face of the yoke flat, OK TO USE THIS PART AGAIN.
If there is heavy fretting in the slot area, DO NOT USE THIS PART AGAIN.
Illustration 10 | g02319695 |
The darker line of wear around the center of the shaft is caused by the lip-type seal. (3) Wear groove |
Transmission and differential yokes can also be damaged by wear of the yoke shaft. The lip-type seals cause wear on the seal contact area of the shaft. “Wear” is defined as being able to feel a step in the seal contact area, as shown in Illustration 10.
If shaft damage is found, Caterpillar recommends machining the yoke face first, if necessary. Then repair the shaft damage.
Procedure to Machine Yoke Faces
- Clean and inspect the yoke thoroughly. If there is any wear of the yoke shaft, refer to the "Repairing Shaft Seal Wear" section.
Show/hide table
Illustration 11 g02319697 (A) Diameter - Carefully install the yoke in a lathe to prevent damage to the seal surface. Use diameter (A) as the surface for the chuck jaws.
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Illustration 12 g02319733 Yoke installed in a lathe chuck - Use a dial indicator equipped with a 7H-1940 Universal Attachment (90°) to check the Total Indicator Reading (TIR) of an area of the yoke face that is not worn. Refer to Illustration 12. The maximum TIR for the yoke face is
0.13 mm (0.005 inch) .Show/hide tableIllustration 13 g02319914 Cutting tools and holder necessary to machine yoke faces. - Use a triangular type carbide/ceramic cutting tool to machine the yoke face, as shown in Illustration 13. Turn large pieces approximately 50 rpm and smaller pieces between 150 and 180 rpm. Use a feed-rate of between
0.13 mm/rev and 0.36 mm/rev (0.005 inches/rev and 0.014 inches/rev) for both sizes. - As the yoke face is machined, make sure that all nicks, pits, and debris are removed.
If more than
0.51 mm (0.020 inch) of material is removed, then DO NOT USE THIS PART AGAIN.Show/hide tableIllustration 14 g02319915 Machined yoke face. - Feel the surface texture with your finger. If the machining grooves cannot be felt, the surface texture is acceptable. If the machining grooves can be felt, use a surface texture analyzer to determine if the surface texture is acceptable. The maximum allowable surface texture is 6.35 µm (250 µinch) or smoother. Refer to Illustration 14.
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NOTICE To reduce fretting in the future, be sure to remove any paint on the contact surfaces of both the yoke and any part fastened to the yoke before installing the yoke on the transmission or differential. Also, tighten all bolts to the correct torque.
- To prevent corrosion, put a thin layer of rust inhibitor or oil on the yoke.
Note: Ensure that the oil or rust inhibitor is removed prior to installation.
Repairing Shaft Seal Wear
Lip-type seals can cause a groove to wear in the contact surface of the mating part. Many times this part could be used again except for the groove wear. Wear sleeves are now available to install over the groove to give a new seal surface to the worn part. The wear sleeve will allow reuse of the worn part and allow the use of the original seal part number. This guideline gives the part numbers of the wear sleeves, the sleeve drivers (installation tools), and the procedure needed to make the repair. Table 4 gives the part number of the sleeve to install according to the size of the shaft. Table 5 provides the part number of the sleeve according to the part number of the yoke or flange being repaired.
Wear Sleeves and Wear Sleeve Drivers
Illustration 15 | g02319987 |
(4) Rolled surface
(5) Driver (6) Driver (7) Driver |
Driver (6) has rolled surface (4).
There is a specific driver to use for installation of each wear sleeve. The drivers are all either a type (5), (6), or (7) as shown in Illustration 15. The type (5) and type (7) drivers have a closed end (shown) and an open end (not shown). These two drivers can be used in only one way to install a wear sleeve. To use type (6) drivers (open on both ends), always put the end that has the rolled (round) part (4), next to the sleeve.
Illustration 16 | g02321214 |
Illustration 16 shows a typical wear sleeve. The wear sleeve is made in one piece and has a wear surface (9) for the seal, and a flange (8). In most applications of the wear sleeve, the flange will be removed.
Application Chart by Reference to Shaft Size | ||
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Shaft Size | Sleeve Part Number | Sleeve Driver |
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(1) | Two wear sleeves available: Width of |
(2) | Two wear sleeves available: Width of |
Note: If a wear sleeve is not available, refer to the "Metal Spray Method to Repair Seal Surfaces" section.
(1) | Refer to Table 4 for the corresponding sleeve driver. |
Wear Sleeve Installation
- Carefully inspect the shaft surface for seal wear. Wear groove (3) shows typical wear caused by a lip-type seal.
Show/hide table
Illustration 18 g02323313 Cleaning method that can be used on yokes, shafts, and flanges. - Clean the wear surface thoroughly with a 180 grit or finer emery cloth. Use a file to remove any nicks or burrs (deep grooves or notches).
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Illustration 19 g02323314 Wear sleeve installation
(3) Wear groove
(8) Flange
(9) Wear surface
(10) Wear sleeve
(11) Mark - Hold wear sleeve (10) in the position shown in Illustration 19, so that the center of new wear surface (9) is over wear groove (3). Then, make a mark (11) that is even with the back of flange (8) on wear sleeve (10). If the flange (8) will be against a shoulder after the sleeve is installed, mark (11) is not needed. Refer to Step 8.
Note: If there is more than one wear groove, make sure that all wear grooves will be covered an even amount.
Show/hide tableIllustration 20 g02323335 Shaft with wear groove
(3) Wear groove - If groove (3) is a deep groove, fill with a powdered metal epoxy and install the wear sleeve before the epoxy becomes hard. If the powdered metal is not needed, put Paint Primer on the area around groove (3). Put a small amount of 9S-3265 Compound on the area around groove (3) and inside of the new wear sleeve.
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Illustration 21 g02323356 Install wear sleeve
(8) Flange
(10) Wear sleeve
(11) Mark - Put wear sleeve (10) in position so flange (8) goes on first, as shown in Illustration 21. Be sure that the wear sleeve is kept straight as during installation. Use the correct sleeve driver and a press to install the wear sleeve in the correct position.
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Illustration 22 g02323535 Drive wear sleeve onto shaft with a press or a soft hammer. - If a press is not available, use a soft hammer with the sleeve driver to install the wear sleeve, as shown in Illustration 22.
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Illustration 23 g02323553 Sleeve driver (6) with roller part (4) - If a type (6) sleeve driver is used (refer to "Wear Sleeves and Wear Sleeve Drivers"), be sure to put the rolled (round) part (4) next to the sleeve.
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Illustration 24 g02323555 Shaft with chamfer
(8) Flange
(12) Chamfer - If there is a chamfer (12) on the original wear surface for the seal, install the wear sleeve far enough so that the end of the wear sleeve is beyond the chamfer, as shown in Illustration 24. If flange (8) of the wear sleeve is against a shoulder, do not remove. If flange (8) is not against a shoulder, it must be removed. Refer to Step 9.
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Illustration 25 g02324933 Remove flange
(8) Flange
(13) Diagonal pliers
(14) Pre-cut line - If flange (8) of the wear sleeve is not against a shoulder, and must be removed, use diagonal pliers (13) to cut flange (8) up to pre-cut line (14).
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Illustration 26 g02324934 Flange removal
(8) Flange
(15) Pliers - Use straight pliers (15) to bend and remove flange (8).
Illustration 17 | g02319695 |
Wear surface of seal with wear groove (3) |
Metal Spray Method to Repair Seal Surfaces
Metal spray is an acceptable method of restoring a surface to the original size. Refer to section "Thermal Spray Procedure". Also, consult the manufacturer of the metal spray equipment for powder recommendations, machine settings, and application procedures. Each step in the procedure is critical in achieving the desired coating bond and surface texture.
Note: Sometimes, a yoke with seal lip damage can be reused without any salvage operations by installing the seal at a different position.
Acceptable surface texture on the shaft seal area must be within
Plunge grinding is the grinding technique that should be used on the shaft sealing surface. This eliminates the possibility of a leak path that can be created if the traverse grinding method is used.
Illustration 27 | g03591670 |
Typical example of a Yoke. |
Note: (C*) is when the other is not given.
Refer to Illustration 27 for dimensions listed in Table 6.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
Radius |
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Illustration 28 | g03591684 |
Typical example of a Yoke. |
Note: (C*) is when the other is not given.
Refer to Illustration 28 for dimensions listed in Table 7.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
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Illustration 29 | g03591695 |
Typical example of a Yoke. |
Note: (C*) is when the other is not given.
Refer to Illustration 29 for dimensions listed in Table 8.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
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Illustration 30 | g03591703 |
Typical example of a Yoke. |
Note: (C*) is when the other is not given.
Refer to Illustration 30 for dimensions listed in Table 9.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
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Illustration 31 | g03591712 |
Typical example of a Yoke. |
Refer to Illustration 31 for dimensions listed in Table 10.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
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Illustration 32 | g03591856 |
Typical example of a Yoke. |
Note: (C*) is when the other is not given.
Refer to Illustration 32 for dimensions listed in Table 11.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
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Illustration 33 | g03591862 |
Typical example of a Yoke. |
Refer to Illustration 33 for dimensions listed in Table 12.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
Radius |
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Illustration 34 | g06407539 |
Typical example of a Yoke. |
Refer to Illustration 34 for dimensions listed in Table 13.
Transmission and Differential Yokes | |||||
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Part Number | Yoke Number | Dimension A | Dimension B | Dimension C | Dimension D
Radius |
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Part Description
Base Metal | Steel Forging |
Hardness | 23-28 Rc |
Arc Spray Equipment and Procedure
Arc Spray Equipment | |
---|---|
Maximum Surface Texture | 6.1 µm (240.00 µinch) |
Reason for Spraying | Seal Wear |
Mating Part Contact Area & Material | Seal |
Arc Spray Equipment Type | SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU |
Wire | TAFA Alcro Wire Top Coat; TAFA 75B Bond Coat |
Finish Thickness | As Required |
Finishing Allowance | |
Spray Angle | 70° to 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | Filtered shop air |
Rotation/Traverse Device | Lathe |
Rotation Speed | |
Surface Preparation Method | Undercut and Grit blast |
Machining Method | Machine |
Equipment Required | Turn (Horizontal or Vertical) Lathe |
Recommended Cutting Tool | ISCAR DNMG 432 TF IC507 |
Blast Media Recommendation | Pressure Type Only (Aluminum Oxide Grit) |
Grinding Equipment | Dunmore Tool Post Grinder |
Recommended Abrasive | Norton 32A 46-H8VBE |
Remarks | 1) No lead on grinding
2) Roundness specification of |
Arc Spray | Procedure | Check List | ||
---|---|---|---|---|
Clean Part | Degrease in hot Aluminum safe cleaner | |||
Undercut | If desired | |||
Chamfer | 30° | |||
Remove Oxide | Use fiber flap brush or Clean/strip disc | |||
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 | |
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Blast Nozzle to Work Distance | |
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Remove Blast Mask | Make sure that surface is clean | |||
Mask for Metal Spray | Antibond or Blue Layout Dye | |||
Metal Spray Equipment Type | Smart Arc by Oerlikon Metco | TAFA | ||
Consumable (Bondcoat) | TAFA 75B | TAFA 75B | ||
Clamp Pressure | |
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Air Jets/Pressure | |
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Arc Load Volts | 30V | 30V | ||
Amps | 125 Amps | 150 Amps | ||
Gun to Work Distance (Standoff) | |
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Spray Rate/Bond Pass | |
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Consumable (Topcoat) | TAFA Alcro | TAFA Alcro | ||
Clamp Pressure | |
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Air Jets/Pressure | |
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Arc Load Volts | 30V | 29V | ||
Amps | 150 Amps | 125 Amps | ||
Gun to Work Distance (Standoff) | |
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Spray Rate/Build Up | |
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Rotation Speed of Part (RPM) | RPM varies depending on diameter (52 to 143 RPM) | |||
Rotation Speed of Part | |
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Traverse Rate of Gun | |
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Gun Fixturing Method | Machine mount or hand held | |||
Finishing Equipment | Lathe | |||
Part/Cutter Rotation Roughing | |
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Part/Cutter Rotation Finishing | |
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Coolant | Oil base synthetic - 40:1 ratio | |||
Traverse Speed | |
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Depth of Rough Cut | |
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Depth of Finish Cut | |
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Additional Finish Method | Grind surface for no lead |
Flame Spray Equipment and Procedure
Flame Spray Equipment | |
---|---|
Maximum Surface Texture | 6.1 µm (240.00 µinch) |
Reason for Spraying | Seal Wear |
Mating Part Contact Area & Material | Seal |
Oerlikon Metco Equipment Type | 6P-II by Oerlikon Metco |
Metco Material | Metco 453 |
Metco Sealer | - |
Finish Thickness | As Required |
Finishing Allowance | |
Spray Angle | 70° to 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Device | Lathe |
Rotation/Traverse Speed | |
Surface Preparation Method | Undercut and Grit Blast |
Finishing Method | Machine |
Machining Equipment Type | Lathe |
Recommended Cutter Grade | C-2, 883 Carboloy or equivalent |
Remarks | 1) No lead on grinding
2) Roundness specification of |
Flame Spray Process (6P) | Procedure | Check List |
---|---|---|
Clean Part | Degrease in hot caustic solution | |
Undercut | To "tru-up" surface | |
Chamfer | 30° | |
Remove Oxide | Use fiber flap brush or Clean/strip disc | |
Clean Spray Area | Metco cleaning solvent or equivalent | |
Mask for Grit Blast | Duct Tape | |
Grit Blast Equipment | Pressure | |
Grit Type and Size | 25 to 40 steel angular grit | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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Remove Blast Mask | Make sure that surface is clean | |
Mask for Metal Spray | Metco Antibond | |
Metal Spray Equipment Type | 6P-II Hand Held Thermo Spray System by Oerlikon Metco | |
Auxiliary Cooling | If desired | |
Nozzle | 6P-C7A-K "K" Nozzle | |
Air Capacity/Pressure | 6P-3/Cooling Air |
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Oxygen Pressure | |
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Oxygen Flow | |
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Fuel Gas Pressure | |
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Fuel Gas Flow | |
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Carrier Gas Pressure | |
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Carrier Gas Flow | |
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Spray Rate/Build Up | |
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Gun to Work Distance | |
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Rotation Speed of Part (RPM) | RPM varies depending on diameter (70 - 143 RPM) | |
Rotation Speed of Part (SFPM) | |
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Traverse Rate of Gun (SFPM) | |
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Gun Fixturing Method | Machine mount | |
Top Coat/Thickness | |
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Finishing Equipment | Lathe | |
Part/Cutter Rotation (SFPM) | |
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Traverse Speed | |
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Depth of Rough Cut | |
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Depth of Finish Cut | |
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Additional Finish Method | Emery cloth for desired finish, no lead |
Crack Detection Methods
NOTICE |
---|
Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings. |
There are five major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Surface Inspection (VT), Liquid Penetrant Testing (PT), Dry / Wet Magnetic Particle Testing (MPT), and Ultrasonic Testing (UT).
Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, Dry/ Wet MPT, and UT are methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most versatile. For example, the PT method can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using the Wet MPT is more accurate. Refer to Table 19 for advantages and disadvantages and Table 20 for standards and requirements for these NDT methods.
Crack Detection Methods Advantages vs. Disadvantages | ||
---|---|---|
Detection Method | Advantages | Disadvantages |
Visual Surface Inspection (VT) | - Least Expensive
- Detects most damaging defects. - Immediate Results - Minimum part preparation |
- Limited to surface-only defects.
- Requires inspectors to have broad knowledge of welding and fabrication in addition to Non-Destructive Testing (NDT). |
Liquid Penetrant Testing (PT) | - Inexpensive
- Minimal Training - Portable - Works on nonmagnetic material. |
- Least Sensitive
- Detects surface cracks only. - Rough or porous surfaces interfere with test |
Dry Magnetic Particle (MPT) | - Portable
- Fast/Immediate Results - Detects surface and subsurface discontinuities |
- Works on magnetic material only.
- Less sensitive than Wet Magnetic Particle Testing (MPT). |
Wet Magnetic Particle (MPT) | - More sensitive than Liquid Penetrant Testing (PT).
- Detects subsurface as much as |
- Requires power for light.
- Works on magnetic material only. - Liquid composition and agitation must be monitored. |
Ultrasonic Testing (UT) | - Most Sensitive
- Detects deep material defects. - Immediate Results - Wide range of materials and thickness can be inspected |
- Most Expensive
- Requires operator training and certification. - Surface must be accessible to probe |
Applicable Crack Detection Standards | |||
---|---|---|---|
Detection Method | Standard | Acceptance
Criteria |
Minimum
Required Personnel Qualifications |
Visual Surface Inspection (VT) | EN-ISO 5817
AWS D1.1 |
EN-ISO 5817 - Level B
AWS D1.1 - Table 6.1 |
EN-ISO 9712
ANSI-ASNT SNT-TC-1A |
Liquid Penetrant Testing (PT) | EN-ISO 3452
ASTM E165 |
EN-ISO 23277
AWS - D1.1 |
EN-ISO 9712
ANSI-ASNT SNT-TC-1A |
Magnetic Particle Testing (MPT) | EN-ISO 17638
ASTM E709 |
EN-ISO 23278 - Level 1
AWS D1.1 - Table 6.1 |
EN-ISO 9712
ANSI-ASNT SNT-TC-1A |
Ultrasonic Testing (UT) | EN-ISO 17640 - Level B
AWS D1.1 |
EN-ISO 11666 Technique 2 - Level 2
AWS D1.1 - Class A - Table 6.3 |
EN-ISO 9712
ANSI-ASNT SNT-TC-1A |
Visual Surface Inspection (VT)
Illustration 35 | g06124166 |
Example of Visual Surface Inspection (VT) Tooling (A) Flashlight (or adequate light source) (B) Magnifying Glass (C) Tape Measure (or other measuring device) (D) Inspection Mirror |
Refer to Tooling and Equipment Table 3 for part numbers.
Components and welds that are to be tested using PT, MPT, or UT shall first be subject to a Visual Surface Inspection (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration 35. Personnel performing VT shall either be trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. Personnel performing VT shall take routine eye exams.
Liquid Penetrant Testing (PT)
Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals. |
Materials and Equipment Required
Refer to Tooling and Equipment Table 3 for part numbers.
- Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.
- Penetrating Oil: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.
- Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrating oil indications.
- Wire Brush: Removes dirt and paint.
- Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
- Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe the area to be tested with a solvent dampened cloth to remove remaining dirt and allow the area to dry. Remove paint where there are visible cracks using paint remover or a wire brush.
Show/hide table
Illustration 37 g06103803 Typical example of applying penetrating oil to areas to be tested. - Apply penetrant by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrant to soak. After the penetrating oil has been allowed to soak, remove the excess penetrating oil with clean, dry wipe.
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Illustration 38 g06103816 Typical example of removing penetrating oil with a cloth. - The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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Illustration 39 g06103820 Typical example of applying the developer. - Before using developer, ensure that the developer is mixed thoroughly by shaking the container. Hold the container approximately
203 - 305 mm (8.0 - 12.0 inch) away from the testing area. Apply an even, thin layer of developer over the testing area. A few thin layers are a better application method than one thick layer.Show/hide tableIllustration 40 g06084042 Typical example of cracks found during Liquid Penetrant Testing (PT). - Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 40. Clean the area of application of the developer with solvent cleaner.
Illustration 36 | g06103795 |
Typical example of pre-cleaning the testing area. |
Dry Magnetic Particle Testing (MPT)
Materials and Equipment Required
Refer to Tooling and Equipment Table 3 for part numbers.
Illustration 41 | g06085930 |
(A) Indications shown by Dry Magnetic Particle Testing (MPT).
(B) Electromagnetic Yoke (C) Dry Powder Bulb |
- Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.
- Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.
- Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.
- Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least
4.5 kg (10 lbs) . - Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.
- All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.
Procedure
- Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.
- Apply the magnetic field using the yoke against the faces and inside diameter of each bore.
- Simultaneously apply the dry powder using the dry powder blower.
- Remove excess powder by lightly blowing away the dry particles.
- Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.
- Observe particles and note if any clusters of particles appear revealing an indication.
- Record the size and shape of any discontinuities or indications found.
Wet Magnetic Particle Testing (MPT)
Materials and Equipment
Refer to Tooling and Equipment Table "Tooling and Equipment" for part numbers.
Illustration 42 | g06085937 |
(A) Indications shown by Wet Magnetic Particle Testing (MPT).
(B) Electromagnetic Yoke (D) Ultraviolet Lamp |
Illustration 43 | g06003178 |
Pear Shaped Centrifuge Tube |
- Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.
- Concentration:
- The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.
- Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a
1 mL (0.034 oz) stem with0.05 mL (0.0017 oz) divisions, refer to Illustration 43. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between0.1 mL (0.0034 oz) and0.25 mL (0.0085 oz) in a100 mL (3.40 oz) sample. - Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
- The oil shall have the following characteristics:
- Low viscosity not to exceed
5 mm2/s (5 cSt) at any temperature at which the vehicle is to be used. - Low inherent fluorescence and be non-reactive.
- Low viscosity not to exceed
- The conditioning agents used in the conditioned water shall have the following characteristics:
- Impart good wetting characteristics and good dispersion.
- Minimize foaming and be non-corrosive.
- Low viscosity shall not exceed a maximum viscosity of
5 mm2/s (5 cSt) at38° C (100° F) . - Non-fluorescent, non-reactive, and odorless.
- Alkalinity shall not exceed a pH of 10.5.
- Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least
4.5 kg (10 lbs) .
Procedure
- Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.
- Apply the magnetic field using the yoke against the surface in the area to be inspected.
Show/hide table
Illustration 44 g03536210 Yoke applied the area to be inspected. - For case hardened and ground surfaces:
- Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 44 for an example of yoke placement.
- Visually inspect for indications of discontinuities using the proper illumination.
- Record the size and shape of any discontinuities found.
Ultrasonic Testing (UT)
Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can be detected by an experienced technician. Refer to Table 20 for crack detection standards.
Refer to Tooling and Equipment Table 3 for part numbers.
- Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.
- There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.
- Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect from the back surface of the material to project the thickness of the material.
- Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.