Thermal Spray Procedures for Wheel Loader Trunnion {0679, 3268} Caterpillar


Thermal Spray Procedures for Wheel Loader Trunnion {0679, 3268}

Usage:

980C 13B
Excavator
330B (S/N: 9HN1-UP)
Integrated Toolcarrier
IT28F (S/N: 1JL1-UP; 3CL1-UP)
IT28G (S/N: 8CR1-UP; DBT1-UP)
IT38F (S/N: 5DR1-UP)
IT38G (S/N: 7BS1-UP; 1CW1-UP)
IT38G Series II (S/N: JAN1-UP; CSX1-UP)
IT62G (S/N: 6PS1-UP)
IT62H (S/N: M5G1-UP)
Wheel Loader
All

Introduction

Table 1
Revision  Summary of Changes in SEBF2142 
06  Added prefixes for NPI and updated copyright 
05  Added one part number.
Updated Introduction. 
04  Added two part numbers. 
03  Corrected Consumable (Topcoat) wire listed in table 4. 
02  Added two part numbers. 

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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 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 not recommended by Caterpillar is used, ensure that it is safe to use. Ensure that the product will not be damaged or 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 2g03071138

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  Steel Tube, Cast Steel, Ductile Iron 
Hardness  28-34 Rc 

Arc Spray Equipment and Procedure

Table 3
Maximum Surface Finish  1.6 Micrometers (63 Microinches) 
Reason for Spraying  Wear, grooving, or corrosion 
Mating Part Contact Area & Material  Bearing 
Arc Spray Equipment Type  SmartArc by Oerlikon Metco PPG Electric Arc Gun, TAFA 8830 MHU, or TAFA 8835 MHU 
Wire  TAFA 90MXC Wire Top Coat, TAFA 75B Bond Coat 
Finish Thickness  As Required 
Finishing Allowance  0.51 mm to 0.64 mm (0.020 in to 0.025 in) per side 
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 
Rotation Speed  92 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit blast 
Equipment Required  Turn (Horizontal or Vertical) Lathe 
Recommended Cutting Tool  ISCAR DNMG 432 TFIC507 
Blast Media Recommendation  Pressure Type Only (Aluminum Oxide Grit) 
Remarks  Refer to Special Instruction, SEHS8728, "Dimensions for Oscillating Rear Axle Components and Supports". 

Table 4
Arc Spray  Procedure  Check List 
Clean Part  Degrease in hot Aluminum safe cleaner   
Undercut  To "tru-up" surface   
Chamfer  If required - 1.0 mm (0.039 in) 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 mm to 150 mm (2.0 in to 6.0 in)   
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  SmartArc by Oerlikon Metco  TAFA   
  Consumable (Bondcoat)  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 in)  128 mm (5.0 in)   
  Spray Rate/Bond Pass  0.038 mm (0.0015 in)/pass  0.038 mm (0.0015 in)/pass   
  Consumable (Topcoat)  TAFA 90MXC  TAFA 90MXC   
  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 (4.0 in)  166 mm (4.0 in)   
  Spray Rate/Build Up  0.058 mm (0.0015 in)/pass  0.058 mm (0.0015 in)/pass   
  Rotation Speed of Part (RPM)  RPM varies depending on diameter (52 RPM to 143 RPM)   
  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  Lathe   
Part/Cutter Rotation Roughing  50 SMPM (150.00 SFPM)   
Part/Cutter Rotation Finishing  75 SMPM (250.00 SFPM)   
Coolant  Oil base synthetic - 40:1 ratio   
Traverse Speed  0.30 mm (0.012 in)   
Depth of Rough Cut  0.51 mm (0.020 in)   
Depth of Finish Cut  0.25 mm (0.010 in)   

Flame Spray Equipment and Procedure

Table 5
Maximum Surface Finish  3.6 Micrometers (140 Microinches) 
Reason for Spraying  Wear 
Mating Part Contact Area & Material  Bearing 
Oerlikon Metco Equipment Type  6PII by Oerlikon Metco 
Oerlikon Metco Material  Oerlikon Metco 453 
Finishing Allowance  0.51 mm to 0.64 mm (0.020 in to 0.025 in) 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 headstock/tailstock arrangement, rotary 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  C-2, 883 Carboloy, or equivalent 
Remarks  Refer to Special Instruction, SEHS8728, "Dimensions for Oscillating Rear Axle Components and Supports". 

Table 6
Flame Spray Process (6P)  Procedure  Check List 
Clean Part  Degrease in hot caustic solution   
Undercut  To "tru-up" surface   
Remove Oxide  Use fiber flap brush, Clean/strip disc   
Clean Spray Area  Oerlikon Metco cleaning solvent or equivalent   
Mask for Blast  Duct Tape   
Blast Equipment  Pressure type only   
Grit Type and Size  24 mesh aluminum oxide   
Blast Air Pressure  690 kPa (100.0 psi)   
Blast Nozzle to Work Distance  51 mm to 150 mm (2.0 in to 6.0 in)   
Remove Blast Mask  Remove mask, make sure that surface is clean   
Mask for Spray  Oerlikon Metco Antibond or blue layout dye   
Spray Equipment Type  6PII by Oerlikon Metco Hand Held Thermo Spray System   
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 gr (3.2 oz) per min   
Gun to Work Distance  230 mm (9.0 in)   
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 mm to 0.15 mm (0.004 in to 0.006 in) per pass   
Finishing Equipment  Lathe   
Part/Cutter Rotation  91.4 SMPM (300.00 SFPM)   
Traverse Speed  0.05 mm to 0.10 mm (0.002 in to 0.004 in) per revolution   
Depth of Rough Cut  0.38 mm to 0.51 mm (0.015 in to 0.020 in) per side   
Depth of Finish Cut  0.25 mm to 0.38 mm (0.010 in to 0.015 in) per side   
Additional Finish Method  Emery cloth for desired finish   

Specifications



Illustration 3g03071178

Table 7
Wheel Loader Trunnion 
Part Number  Dimension A 
6S-3975  42.05 ± 0.07 mm (1.656 ± 0.002 in) 
7K-0686  126.80 ± 0.08 mm (4.992 ± 0.003 in) 
258-6940 
6S-4072  115.09 ± 0.08 mm (4.531 ± 0.003 in) 
4E-3159  88.82 ± 0.08 mm (3.497 ± 0.003 in) 
8R-2527 
108-4152 
6K-9073 
9V-1260 
8R-2584  101.45 ± 0.08 mm (3.994 ± 0.003 in) 
7K-7430 
9V-1258 
4E-4007  126.80 ± 0.08 mm (4.992 ± 0.003 in) 
9C-9191 
2K-0499 
242-6251  156 ± 0.08 mm (6.141 ± 0.003 in) 
467-0997 
510-2637  154 ± 0.08 mm (6.063 ± 0.003 inch) 
434-7982  174.50 ± 0.08 mm (6.870 ± 0.003 inch) 
7K-1743  228.52 ± 0.08 mm (8.997 ± 0.003 in) 
105-8702  265.60 ± 0.08 mm (10.457 ± 0.003 in) 
5S-0090  304.75 ± 0.05 mm (11.998 ± 0.002 in) 
2V-6129 
118-9403 
209-6694 
4E-0078  330.15 ± 0.05 mm (12.998 ± 0.002 in) 
7K-8933  304.75 ± 0.05 mm (11.998 ± 0.002 in) 
1V-8254  330.15 ± 0.05 mm (12.998 ± 0.002 in) 
205-8347 
8R-5720  428.80 ± 0.05 mm (16.882 ± 0.002 in) 
244-1106  370 ± 0.05 mm (14.57 ± 0.002 in) 

Caterpillar Information System:

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