Thermal Spray Procedures for Torque Converter Turbine Wheel {0679, 3101, 3131} Caterpillar


Thermal Spray Procedures for Torque Converter Turbine Wheel {0679, 3101, 3131}

Usage:

769C 01X
Articulated Truck
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Backhoe Loader
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Challenger
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Combine
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Compact Wheel Loader
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Integrated Toolcarrier
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Landfill Compactor
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Load Haul Dump
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Off-Highway Truck/Tractor
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Wheel Tractor-Scraper
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Introduction

Table 1
Revision  Summary of Changes in SEBF2112 
04  Added additional prefixes for New Product Introduction (NPI) 
03  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018.
Removed old point of contacts.
Added new point of contact. 
02  Republished due to errors in publishing process on previous revision level. 
01  Change powder recommendation, added confidentiality statement and safety graphic. 
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 further information on the equipment needed to perform thermal spray processes, refer to the following publications:

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.

  • 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, procedure, 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 2g03020465

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. Ensure that the tools, procedures, work methods, and operating techniques are safe. Ensure that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must 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  Aluminum 
Hardness  N/A 

Flame Spray Equipment and Procedure

Table 3
Maximum Surface Finish  3.175 micrometers (125.0000 Microinches) 
Reason for Spraying  Wear 
Mating Part Contact Area & Material  Controlled clearance between turbine wheel and stator 
Metco Equipment Type  6P-II 
Metco Material  Metco 452 or 453 
Finished Thickness  As required 0.38 mm (0.015 inch) 
Finishing Allowance  0.51 mm (0.020 inch) per side 
Spray Angle  90° 
Substrate Pre-Heat Temperature  None 
Substrate Temperature During Spraying Not to Exceed  94° C (200° F) 
Auxiliary Cooling  AJ, if required 
Rotation/Traverse Device  Lathe or turntable 
Rotation/Traverse Speed  91.4 SMPM (300.00 SFPM) 
Surface Preparation Method  Grit Blast 
Finishing Method  Machine 
Machining Equipment Type  Lathe 
Recommended Cutter Grade  883 Carboloy or equivalent 
Remarks  Refer to SEBF8008 "Turbine Wheel for Torque Converters Used with Power Shift Transmissions" for more information on checking for acceptable running clearance after rebuilding.
Avoid large buildups on aluminum as cooling and expansion rates must be closely watched. 

Table 4
Flame Spray Process (6P)  Procedure  Check List 
Clean Part  Use METCO Cleaning Solvent or equivalent   
Undercut  Not required   
Chamfer  All edges - 45° x 0.76 mm (0.030 inch)   
Remove Oxide  Emery paper or glass beading   
Mask for Blast  Use metal mask   
Blast Equipment  Pressure blast   
Grit Type and Size  G-25 angular steel   
Blast Air Pressure  620 kPa (90.0 psi)   
Blast Nozzle to Work Distance  63.5 mm (2.50 inch)   
Remove Blast Mask  N/A   
Mask for Spray  Use blast mask and masking compound   
Spray Equipment Type  6PII   
Auxiliary Cooling  Not required   
Nozzle  6P7C-B "B" nozzle - requires 6P-600 siphon plug   
Air Capacity/Pressure  6P-3/Pinch air - 140 kPa (20.0 psi)   
Oxygen Pressure  158.6 kPa (23.00 psi)   
Oxygen Flow  962.77 L/h (34.000 cfh)   
Fuel Gas Pressure  100 kPa (15.0 psi)   
Fuel Gas Flow  962.77 L/h (34.000 cfh)   
Carrier Gas Pressure  380 kPa (55.0 psi)   
Carrier Gas Flow  1050 L/h (37.0 cfh)   
Spray Rate/Bond Pass  Not required   
Spray Rate/Build Up  2.27 Kg (5.000 Lbs) per hour 0.51 mm (0.002 inch) per pass   
Gun to Work Distance  177.8 mm (7 inch)   
Rotation Speed of Part  60.96 SMPM (200.000 SFPM) minimum   
Traverse Rate of Gun  15.24 SMPM (50.000 SFPM)   
Gun Fixturing Method  Hand held   
Top Coat/Thickness  As required   
Finishing Equipment  Lathe   
Part/Cutter Rotation  182.88 SMPM (600.000 SFPM) minimum   
Traverse Speed  0.51 mm (0.002 inch) to 0.10 mm (0.004 inch) per revolution   
Depth of Rough Cut  0.25 mm (0.010 inch)   
Depth of Finish Cut  0.13 mm (0.005 inch)   


Illustration 3g03020518

For dimensional specifications refer to SEBF8008.

Caterpillar Information System:

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