Thermal Spray Procedures for Wheel Dozer and Integrated Toolcarrier Axle Housing {0679, 3260} Caterpillar


Thermal Spray Procedures for Wheel Dozer and Integrated Toolcarrier Axle Housing {0679, 3260}

Usage:

814 14R
Integrated Toolcarrier
All
Wheel Dozer
All

Introduction

Table 1
Revision  Summary of Changes in SEBF2185 
03  Added serial number prefixes for NPI, updated intro and copyright 
02  Changed supplier name from Sulzer Metco to Oerlikon Metco. 
01  Added confidentiality statement, Think Safety graphic, and updated Praxair TAFA arc spray system. 
00  Information removed from SERF8473 (Arc Spray Guide CD) and 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 in order 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 in order 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.

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

  • Special Instruction, SEBF9236, "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components"

  • Special Instruction, SEBF9238, "Fundamentals of Arc Spray for Reconditioning Components"

  • Special Instruction, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components"

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information



Illustration 1g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that the procedure is safe for you and for other people to use. Ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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

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 2g03119256

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, or the repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Part Description

Table 2
Base Metal  Wheel Dozer: Ductile Iron
Integrated Toolcarrier: Cast Iron 
Hardness  Wheel Dozer: 28-34 Rc
Integrated Toolcarrier: 156 - 217 BHN 

Arc Spray Equipment and Procedure

Table 3
Maximum Surface Finish  3.5 Micrometer (138 Microinches) 
Reason for Spraying  Wear, grooving, or corrosion 
Mating Part Contact Area & Material  Bearing 
Arc Spray Equipment Type  SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU 
Wire  TAFA 30T Wire Top Coat, TAFA 75B Bond Coat 
Finish Thickness  As Required 
Spray Angle  90° 
Substrate Pre-Heat Temperature  66° C (150° F) Do not direct arc on area to be sprayed 
Substrate Temperature During Spraying Not to Exceed  148° C (300° F) 
Auxiliary Cooling  Filtered shop air 
Rotation/Traverse Device  Lathe or headstock/tailstock arrangement, rotary turntable 
Rotation Speed  92 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit blast if necessary 
Equipment Required  Horizontal or Vertical Lathe 
Recommended Cutting Tool  ISCAR DNMG 432 TFIC507 
Blast Media Recommendation  Pressure Type Only (Aluminum Oxide Grit) 

Table 4
Arc Spray  Procedure  Check List 
Clean Part  Degrease in hot caustic solution   
Undercut  If desired   
Chamfer  If required - 1.0 mm (0.039 inch) x 45°   
Remove Oxide  Use emery cloth or glass bead blaster   
Clean Spray Area  Commercial degreaser   
Mask for Grit Blaster  Duct tape, metal shield, or rubber   
Grit Blast Equipment  Pressure type only   
Grit Type and Size  20 mesh aluminum oxide   
Blast Air Pressure  690 kPa (100.0 psi)   
Blast Nozzle to Work Distance  51 to 150 mm (2.0 to 6.0 inch)   
Remove Blast Mask  Remove mask material, make sure that surface is clean   
Mask for Metal Spray  Duct tape, metal shield, or rubber   
Metal Spray Equipment Type  Smart Arc by Oerlikon Metco  TAFA   
  Consumable (Bond coat)  TAFA 75B  TAFA 75B   
  Clamp Pressure  275 kPa (40 psi)     
  Air Jets/Pressure  415 kPa (60 psi)  415 kPa (60 psi)   
  Arc Load Volts  30V  30V   
  Amps  125 Amps  150 Amps   
  Gun to Work Distance (Standoff)  128 mm (5.0 inch)  128 mm (5.0 inch)   
  Spray Rate/Bond Pass  0.038 mm (0.0015 inch)/pass  0.038 mm (0.0015 inch)/pass   
  Consumable (Topcoat)  TAFA 30T  TAFA 30T   
  Clamp Pressure  275 kPa (40 psi)     
  Air Jets/Pressure  415 kPa (60 psi)  415 kPa (60 psi)   
  Arc Load Volts  31V  31V   
  Amps  150 Amps  175 Amps   
  Gun to Work Distance (Standoff)  166 mm (6.5 inch)  166 mm (6.5 inch)   
  Spray Rate/Build Up  0.058 mm (0.0023 inch)/pass  0.058 mm (0.0023 inch)/pass   
  Rotation Speed of Part (RPM)  RPM varies depending on diameter   
  Rotation Speed of Part  92 SMPM (300 SFPM)   
  Traverse Rate of Gun  11 SMPM (40 SFPM)   
Gun Fixturing Method  Machine mount or hand held   
Finishing Equipment  Milling Machine or Lathe   
Part/Cutter Rotation Roughing  50 SMPM (150 SFPM)   
Part/Cutter Rotation Finishing  75 SMPM (250 SFPM)   
Coolant  Oil base synthetic - 40:1 ratio   
Traverse Speed  0.30 mm (0.012 inch)   
Depth of Rough Cut  0.51 mm (0.020 inch)   
Depth of Finish Cut  0.25 mm (0.010 inch)   

Flame Spray Equipment and Procedure

Table 5
Maximum Surface Finish  3.5 Micrometer (138 Microinches) 
Reason for Spraying  Wear, grooving, or corrosion 
Mating Part Contact Area & Material  Bearing race 
Metco Equipment Type  6P-II by Oerlikon Metco 
Metco Material  Metco 453 
Finish Thickness  As Required 
Finishing Allowance  0.51 to 0.64 mm (0.020 to 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 turntable 
Rotation/Traverse Speed  91.4 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit Blast 
Finishing Method  Machine 
Machining Equipment Type  Lathe or Horizontal Mill 
Recommended Cutter Grade  C-2, 883 Carboloy or equivalent 

Table 6
Flame Spray Process (6P)  Procedure  Check List 
Clean Part  Degrease in hot caustic solution   
Undercut  To "tru-up" surface   
Chamfer  If required - 1.0 mm (0.039 inch) x 45°   
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  20 mesh aluminum oxide   
Blast Air Pressure  690 kPa (100.0 psi)   
Blast Nozzle to Work Distance  51 to 150 mm (2.0 to 6.0 inch)   
Remove Blast Mask  Remove mask, make sure that surface is clean   
Mask for Spray  Metco Antibond or blue layout dye   
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 140 - 170 kPa (20.0 - 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 lb) per hour or 90 g (3.2 oz) per min   
Gun to Work Distance  230 mm (9.0 inch)   
Rotation Speed of Part (RPM)  RPM varies depending on diameter   
Rotation Speed of Part  91.4 SMPM (300.00 SFPM)   
Traverse Rate of Gun  15.24 SMPM (50.000 SFPM)   
Gun Fixturing Method  Machine mount or hand held   
Top Coat/Thickness  0.10 to 0.15 mm (0.004 to 0.006 inch) per pass   
Finishing Equipment  Lathe or Horizontal Mill   
Part/Cutter Rotation  91.4 SMPM (300.00 SFPM)   
Traverse Speed  0.05 to 0.10 mm (0.002 to 0.004 inch) per revolution   
Depth of Rough Cut  0.38 to 0.51 mm (0.015 to 0.020 inch) per side   
Depth of Finish Cut  0.25 to 0.38 mm (0.010 to 0.015 inch) per side   
Additional Finish Method  Emery cloth for desired finish   

Specifications



Illustration 3g03119317

Table 7
Wheel Dozer Axle Housing 
Part No.  Dimension C 
119-1048  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch) 
119-1051  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch) 
119-1054  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch) 
9U-2790  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch) 
9U-2791  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch) 
7I-4147  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch) 
7I-4148  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch) 

Table 8
IT Axle Housing 
Part No.  Dimension C 
8R-0250  136.475 ± 0.035 mm (5.3730 ± 0.0014 inch) 
8R-1024  136.475 ± 0.035 mm (5.3730 ± 0.0014 inch) 
8R-4089  136.475 ± 0.035 mm (5.3730 ± 0.0014 inch) 
8R-4090  136.475 ± 0.035 mm (5.3730 ± 0.0014 inch) 
117-3290  114.950 ± 0.035 mm (4.5256 ± 0.0014 inch) 
117-3291  114.950 ± 0.035 mm (4.5256 ± 0.0014 inch) 
117-3292  114.950 ± 0.035 mm (4.5256 ± 0.0014 inch) 
117-3293  114.950 ± 0.035 mm (4.5256 ± 0.0014 inch) 
104-9800  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 
104-9801  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 
8R-1979  136.475 ± 0.035 mm (5.3730 ± 0.0014 inch) 
8R-1980  136.475 ± 0.035 mm (5.3730 ± 0.0014 inch) 
8R-2528  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 
8R-2529  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 
8R-2530  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 
8R-2531  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 
115-5820  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 
116-4585  125.374 ± 0.035 mm (4.9360 ± 0.0014 inch) 

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