- Engine:
- 1673C (S/N: 69D1-UP; 76R1-UP)
- 3126 (S/N: CKK1-UP; 6MK1-UP; 1WM1-UP; 3TR1-UP; 9ZR1-UP; 8HW1-UP; 7LZ1-UP)
- 3126B (S/N: BKD1-UP; BEJ1-UP; 1AJ1-UP; 5GL1-UP; 8YL1-UP; DCS1-UP; 7AS1-UP; 8SZ1-UP)
- 3176 (S/N: 2YG1-UP; 7LG1-UP)
- 3176B (S/N: 9CK1-UP; 9WK1-UP; 3NL1-UP)
- 3176C (S/N: 2AW1-UP)
- 3196 (S/N: 1DW1-UP)
- 3306 (S/N: 4WB1-UP; 7HB1-UP; 2ZC1-UP; 23C1-UP; 66D1-UP; 67D1-UP; 7KF1-UP; 76R1-UP; 64Z1-UP; 84Z1-UP; 85Z1-UP)
- 3306B (S/N: 7JB1-UP; 5JC1-UP; 5KD1-UP; 1DG1-UP; 3RG1-UP; 2AJ1-UP; 8JJ1-UP; 9SL1-UP; 1BM1-UP; 2TM1-UP; 9NR1-UP; 1RS1-UP; 9DS1-UP; 5GZ1-UP; 63Z1-UP)
- 3306C (S/N: 7RJ1-UP; 9TL1-UP; 3KS1-UP; 2AZ1-UP)
- 3406 (S/N: 92U1-UP)
- 3406B (S/N: 4TB1-UP; 7FB1-UP; 8TC1-UP; 4MG1-UP; 5YG1-UP; 3ZJ1-UP; 5KJ1-UP; 2EK1-UP; 4CK1-UP; 4JK1-UP)
- 3406C (S/N: 2WB1-UP; 4MG1-UP; 4RG1-UP; 3ZJ1-UP; 5KJ1-UP; 4CK1-UP)
- 3406E (S/N: 5EK1-UP; 1MM1-UP; 2WS1-UP; 5DS1-UP; 6TS1-UP; 1LW1-UP)
- 3408 (S/N: 67U1-UP; 99U1-UP; 28V1-UP; 78Z1-UP)
- 3408B (S/N: 67U1-UP; 99U1-UP; 28V1-UP; 78Z1-UP)
- 3408C (S/N: 67U1-UP; 99U1-UP; 78Z1-UP)
- 3412 (S/N: 2WJ1-UP; BDT1-UP; 81Z1-UP)
- 3412C (S/N: 81Z1-UP)
- 3412E (S/N: 4CR1-UP; BFT1-UP)
- 3508 (S/N: 1ZF1-UP; 6TJ1-UP; 5XM1-UP; 3LS1-UP; 3PS1-UP; 95Y1-UP; 96Y1-UP; 97Y1-UP; 23Z1-UP; 68Z1-UP; 69Z1-UP; 70Z1-UP)
- 3508B (S/N: 4GM1-UP; C8R1-UP; 5PS1-UP; 2HW1-UP)
- 3512 (S/N: 3YF1-UP; 2WK1-UP; 1LM1-UP; 6PM1-UP; 3MS1-UP; 3RS1-UP; 3WS1-UP; 49Y1-UP; 50Y1-UP; 51Y1-UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-UP)
- 3512B (S/N: 2AF1-UP)
- 3516 (S/N: 4XF1-UP; 9KF1-UP; 4MJ1-UP; 5SJ1-UP; 7KM1-UP; 3SS1-UP; 25Z1-UP; 27Z1-UP; 28Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP)
- C-10 (S/N: MBJ1-UP; 2PN1-UP; 3CS1-UP; 8YS1-UP; BCX1-UP)
- C-12 (S/N: CPD1-UP; BDL1-UP; MBL1-UP; 1YN1-UP; 2KS1-UP; 9NS1-UP)
- C-15 (S/N: EGH1-UP; MBN1-UP; 6NZ1-UP; 9NZ1-UP)
- C-16 (S/N: W1A1-UP; 7CZ1-UP)
- C15 (S/N: MHP1-UP; SDP1-UP; BXS1-UP; MXS1-UP; NXS1-UP; RKS1-UP)
- D333C (S/N: 23C1-UP; 66D1-UP; 67D1-UP)
- D342 (S/N: 31B1-UP; 32B1-UP)
- D342C (S/N: 31B1-UP; 32B1-UP)
- D343 (S/N: 33B1-UP; 62B1-UP)
- D346 (S/N: 39J1-UP; 40J1-UP; 98N1-UP)
- D348 (S/N: 36J1-UP; 38J1-UP; 57K1-UP)
- D349 (S/N: 61P1-UP; 62P1-UP; 32R1-UP)
- G342 (S/N: 31B1-UP)
- 3126 (S/N: CKK1-UP; 6MK1-UP; 1WM1-UP; 3TR1-UP; 9ZR1-UP; 8HW1-UP; 7LZ1-UP)
- Generator Set:
- 3406 GEN SET (S/N: 75Z1-UP)
- 3406B GEN SET (S/N: 2WB1-UP; 4RG1-UP; 4PM1-UP)
- 3406C GEN SET (S/N: 4JK1-UP; 4ZR1-UP; 1LS1-UP; 8FS1-UP)
- 3406E GEN SET (S/N: 9NN1-UP)
- 3456 GEN SET (S/N: BGA1-UP; EPE1-UP)
- 3406B GEN SET (S/N: 2WB1-UP; 4RG1-UP; 4PM1-UP)
- Industrial Engine:
- 3406 IND (S/N: WJA1-UP; 6TB1-UP; 90U1-UP)
- 3406C IND (S/N: 3ER1-UP; 4GW1-UP)
- 3406E IND (S/N: 6BR1-UP)
- 3408C IND (S/N: 9ER1-UP)
- 3412E IND (S/N: BDT1-UP)
- 3456 IND (S/N: 3LW1-UP)
- C-10 PETROLEUM (S/N: Z2B1-UP)
- C-16 IND (S/N: BFM1-UP)
- C15 IND (S/N: JRE1-UP; MCW1-UP)
- C15 INDUSTRIAL (S/N: JKG1-UP; JAS1-UP)
- 3406C IND (S/N: 3ER1-UP; 4GW1-UP)
- Marine Engine:
- 3126B MARINE (S/N: 9ZF1-UP; 3GS1-UP)
- 3176C MARINE (S/N: 6BW1-UP)
- 3196 MARINE (S/N: 2XR1-UP)
- 3406C MARINE (S/N: 4TB1-UP; 1SS1-UP)
- 3406E MARINE (S/N: 9WR1-UP)
- 3408C MARINE (S/N: 1TS1-UP)
- 3412E MARINE (S/N: 9KS1-UP; 9PW1-UP)
- C-12 MARINE (S/N: K1M1-UP; 9HP1-UP)
- C12 MARINE (S/N: NFL1-UP; C1Z1-UP)
- C15 MARINE (S/N: RLA1-UP)
- 3176C MARINE (S/N: 6BW1-UP)
- Truck Engines:
- 3126E (S/N: DPF1-UP; CKM1-UP; CRP1-UP; HEP1-UP; 9SZ1-UP)
- 3406C TRUCK (S/N: 8PN1-UP)
- Petroleum Engine:
- 3126B PETROLEUM (S/N: Z2A1-UP)
- 3412E PETROLEUM (S/N: Z2D1-UP)
- C-15 PETROLEUM (S/N: Z2C1-UP)
- C15 PETROLEUM (S/N: JDY1-UP)
- 3412E PETROLEUM (S/N: Z2D1-UP)
Introduction
Revision     | Summary of Changes in SEBF2125     |
06     | Replaced TAFA 60T wire with TAFA Alcro wire.     |
05     | Added serial number prefixes     |
04     | Changed supplier name from Sulzer Metco to Oerlikon Metco.     |
03     | Added serial number prefixes     |
02     | Added confidentiality statement and updated Praxair TAFA arc spray system.     |
01     | Added serial number prefixes     |
00     | Information removed from SERF8473 (Arc Spray Guide), SERF8704 (Flame Spray Guide CD) and formatted for delivery in SIS.     |
© 2015 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
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 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 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 specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should 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. 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. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must 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.
Part Description
Base Metal     | Cast Iron     |
Hardness     | N/A     |
Arc Spray Equipment and Procedure
Maximum Surface Finish     | 3.5 Micrometers (140 Microinches)     |
Reason for Spraying     | High temperature oxidation     |
Mating Part Contact Area & Material     | Cast iron exhaust manifold     |
Arc Spray Equipment Type     | SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU     |
Wire     | TAFA Alcro Wire Top Coat, TAFA 75B Wire Bond Coat     |
Finish Thickness     | As required     |
Finishing Allowance     | 0.51 to 0.64 mm (0.020 ± 0.025 inch)     |
Spray Angle     | 90° to part     |
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     | If desired     |
Rotation/Traverse Device     | Lathe or turntable     |
Rotation/Traverse Speed     | 61 to 77 SMPM (200.00 to 250.00 SFPM)     |
Surface Preparation Method     | Undercut and Grit blast     |
Machining Method     | Machine     |
Equipment Required     | Turn (Lathe)     |
Recommended Cutting Tool     | ISCAR DNMG 432 TFIC507     |
Blast Media Recommendation     | Pressure Type Only (Aluminum Oxide Grit)     |
Arc Spray     | Procedure     | Check List     | ||
Clean Part     | Degrease in hot caustic solution     |     | ||
Undercut     | To "tru-up" surface (if required)     |     | ||
Remove Oxide     | Use fiber flap wheel or clean/strip disc     |     | ||
Clean Spray Area     | Commercial degreaser     |     | ||
Mask for Grit Blast     | Duct tape     |     | ||
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     | Make sure that surface is clean     |     | ||
Mask for Metal Spray     | Anti-bond or Blue Layout Dye     |     | ||
Metal Spray Equipment Type     | Smart Arc 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 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 Alcro     | TAFA Alcro     |     |
    | Clamp Pressure     | 275 kPa (40 psi)     |
    |     |
    | Air Jets/Pressure     | 415 kPa (60 psi)     |
415 kPa (60 psi)     |
    |
    | Arc Load Volts     | 30V     | 29V     |     |
    | Amps     | 150 Amps     | 125 Amps     |     |
    | Gun to Work Distance (Standoff)     | 76 mm (3.0 inch)     |
76 mm (3.0 inch)     |
    |
    | Spray Rate/Build Up     | 0.038 mm (0.0015 inch)/pass     |
0.038 mm (0.0015 inch)/pass     |
    |
    | Rotation Speed of Part (RPM)     | Set RPM for desired SFPM     |     | |
    | Rotation Speed of Part     | 92 SMPM (300.00 SFPM)     |
    | |
    | Traverse Rate of Gun     | 11 SMPM (36.00 SFPM)     |
    | |
Gun Fixturing Method     | Hand held     |     | ||
Finishing Equipment     | Lathe (Mounting pad surface bottom to centerline of bore dimension must be the same. It is recommended that a new, unused part is used to obtain and set correct centerline distance BEFORE boring the (I.D.) coating.)     |     | ||
Part/Cutter Rotation (Roughing)     | 50 SMPM (150.00 SFPM)     |
    | ||
Part/Cutter Rotation (Finishing)     | 75 SMPM (200.00 SFPM)     |
    | ||
Coolant     | Oil based synthetic - 40:1 ratio     |     | ||
Traverse Speed     | 0.30 mm (0.012 inch) per revolution     |
    | ||
Depth of Rough Cut     | 0.51 mm (0.020 inch) per side max     |
    | ||
Depth of Finish Cut     | 0.25 mm (0.010 inch) per side max     |
    |
Flame Spray Equipment and Procedure
Maximum Surface Finish     | 3.5 Micrometers (140 Microinches)     |
Reason for Spraying     | High temperature oxidation     |
Mating Part Contact Area & Material     | Cast iron exhaust manifold     |
Oerlikon Metco Equipment Type     | 6P-II by Oerlikon Metco     |
Metco Material     | Metco 452 or 453     |
Finish Thickness     | As required     |
Finishing Allowance     | 0.51 to 0.64 mm (0.020 to 0.025 inch) per side     |
Spray Angle     | 90° to part     |
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     | 61 to 77 SMPM (200.00 to 250.00 SFPM)     |
Surface Preparation Method     | Undercut and Grit Blast     |
Finishing Method     | Machine     |
Machining Equipment Type     | Lathe     |
Recommended Cutter Grade     | C-2, 883 Carboloy or equivalent     |
Flame Spray Process (6P-II)     | Procedure     | Check List     |
Clean Part     | Degrease in hot caustic solution     |     |
Undercut     | To "tru-up" surface (if required)     |     |
Mask for Grit Blast     | No     |     |
Grit Blast Equipment     | Pressure     |     |
Grit Type and Size     | 25/40 steel angular grit     |     |
Blast Air Pressure     | 620 kPa (90.0 psi)     |
    |
Blast Nozzle to Work Distance     | 51 to 63.5 mm (2.0 to 2.50 inch)     |
    |
Remove Blast Mask     | Remove mask, make sure that surface is clean     |     |
Mask for Metal Spray     | Metco Anti-Bond     |     |
Metal Spray Equipment Type     | 6P-II Hand Held Thermo Spray System by Oerlikon Metco     |     |
Auxiliary Cooling     | If desired     |     |
Nozzle     | 6P7C-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 (12.00 lb)/hr or 90 gr (3.2 oz)/min     |
    |
Gun to Work Distance     | 230 mm (9.0 inch)     |
    |
Rotation Speed of Part     | Set RPM for desired SFPM     |     |
Traverse Rate of Gun     | 61 to 77 SMPM (200.00 to 250.00 SFPM)     |
    |
Gun Fixturing Method     | Hand held     |     |
Top Coat/Thickness     | 0.10 to 0.15 mm (0.004 to 0.006 inch) per pass until required build-up achieved     |
    |
Finishing Equipment     | Lathe (Mounting pad surface bottom to centerline of bore dimension must be the same. It is recommended that a new, unused part is used to obtain and set correct centerline BEFORE boring the (I.D.) coating.)     |     |
Part/Cutter Rotation     | 46 to 55 SMPM (150.00 to 180.00 SFPM)     |
    |
Traverse Speed     | 0.08 mm (0.003 inch) per revolution or less     |
    |
Depth of Rough Cut     | 0.38 to 0.51 mm (0.015 to 0.020 inch) per side     |
    |
Depth of Finish Cut     | 0.25 mm (0.010 inch) per side or less     |
    |
Specifications
Illustration 3 | g03046696 |
Exhaust Manifold (I.D. & O.D.)     | ||||||
Front Part No.     | Center Part No.     | Rear Part No.     | Male (A)     | Female (B)     | ||
mm | in | mm | in     | |||
2S-7268, 5N-8657     | -     | 3S-2252     | 69.16 3     | 2.723 3     | 69.85 3     | 2.750 3     |
7M-7140     | 2S-2938     | 2S-2939     | 92.00 1     | 3.622 1     | 92.08 1     | 3.625 1     |
1P-1387     | 3P-0038     | 3P-0038     | 101.52 1     | 3.997 1     | 101.60 1     | 4.000 1     |
2P-4597     | 6N-7295     | -     | 88.77 1     | 3.495 1     | 88.90 1     | 3.500 1     |
7N-3952, 5N-9055     | 7N-7739, 7N-3953, 5N-9055 | 88.72 1     | 3.493 1     | |||
127-3467     | 156-0223     | 127-3467     | 55.001     | 2.165 1     | 55.08 1     | 2.168 1     |
7E-7890, 4P-8280     | 7E-7891, 105-4233     | 7E-7892, 4P-8279     | 58.00 1     | 2.28 1     | 55.08 1     | 2.168 1     |
4P-8279     | 115-2989     | 4P-8280     | 58.00 1     | 2.2831     | 55.08 1     | 2.168 1     |
7L-0383     | -     | 7L-0382     | 66.60 1     | 2.625 1     | 66.68 1     | 2.625 1     |
8N-5384     | 7C-8281     | 8N-5386     | 70.00 2     | 2.756 2     | 70.08 2     | 2.759 2     |
(various)     | (various)     | (various)     | 79.30 1     | 3.122 1     | 79.38 1     | 3.1251     |
(various)     | (various)     | (various)     | 76.20 1     | 3.000 1     | 76.261     | 3.002 1     |
1 Tolerance is ± 0.03 mm (0.001 inch)
2 Tolerance is ± 0.03 mm (0.001 inch)
3 Tolerance is ± 0.05 mm (0.002 inch)