- Articulated Truck
- All
- Integrated Toolcarrier
- All
- Landfill Compactor
- 826K (S/N: 2L31-UP; 2T61-UP)
- Soil Compactor
- 825K (S/N: 2L91-UP; 2T91-UP)
- Wheel Dozer
- All
- Wheel Loader
- All
- Wheel Tractor-Scraper
- All
Introduction
Revision | Summary of Changes in SEBF2137 |
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11 | Added detail to summary of changes of revision -10 and changed title from "Thermal Spray Procedures for Wheel Loader, Wheel Dozer, Compactor, Integrated Toolcarrier, Articulated Truck, and Wheel Tractor Scraper - Differential Carrier Assembly" to "Thermal Spray Procedures of Differential Carrier Assemblies for Wheel Loader, Wheel Dozer, Compactor, Integrated Toolcarrier, Articulated Truck, and Wheel Tractor Scraper (WTS)." Updated References Table 2 and added blank cells to Tables 3,4, and 5. |
10 | Added 11 new serial number prefixes for New Product Introduction (NPI). Corrected dimension for part number Added Illustration 6 and Table 6 to cover articulated truck carrier housing assembly. |
09 | Added new serial number prefixes for New Product Introduction.
Arranged tables in alpha numeric sequence. |
08 | Updated copyright and added serial numbers for effectivity and added 3 part numbers |
07 | Added 2 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.
For further information on the equipment needed to perform thermal spray processes, refer to the References Table 2.
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 Differential Carrier Assembly. 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.
References
References | |
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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" |
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 |
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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. |
Specifications
Illustration 3 | g03832003 |
Wheel Loader, Wheel Dozer, Integrated Toolcarrier, Articulated Truck, Load Haul Dump |
Differential Carrier Assembly Acceptable Dimensions and Tolerances | Record Actual Dimensions | |||
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Illustration 4 | g03334613 |
Articulated Truck |
Articulated Truck Carrier Assembly Acceptable Dimensions and Tolerances | Record Actual Dimensions | |||
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Illustration 5 | g03832046 |
Wheel Tractor Scraper (WTS) |
Wheel Tractor Scraper (WTS) Differential Carrier Assembly Acceptable Dimensions and Tolerances | Record Actual Dimensions | |||
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Illustration 6 | g06428232 |
Articulated Truck Carrier Housing Assembly |
Articulated Truck Carrier Housing Assembly Acceptable Dimensions and Tolerances | ||||||
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Part Number | Dimension C | Dimension D | Dimension E | Dimension F | Dimension G | Dimension H |
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Part Description
Base Metal | Wheel Loader, Wheel Dozer, Articulated Truck, and Wheel Tractor Scraper: Ductile Iron
Integrated Toolcarrier: Cast Iron |
Hardness | Wheel Loader, Wheel Dozer, Articulated Truck, and Wheel Tractor Scraper: 28-34 Rc
Integrated Toolcarrier: 156 - 217 BHN |
Arc Spray Equipment and Procedure
NOTICE |
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Mask off all surfaces that are not to be metal sprayed. |
Arc Spray Information Details | |
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Maximum Surface Texture | Wheel Loader and Wheel Tractor Scraper: Articulated Truck: Wheel Dozer and Integrated Toolcarrier: |
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 30T Wire Top Coat, TAFA 75B Bond Coat |
Finish Thickness | As Required |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | Filtered shop air |
Rotation/Traverse Device | Lathe or headstock / tailstock arrangement, rotary turntable |
Rotation Speed | |
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) |
Remarks | Before machining, bolt the caps into place to hold concentricity. |
Arc Spray | Procedure | Check List | ||
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Clean Part | Degrease in hot caustic solution | |||
Undercut | If desired | |||
Chamfer | If required - |
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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 | |
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Blast Nozzle to Work Distance | |
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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 | |
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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 30T | TAFA 30T | ||
Clamp Pressure | |
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Air Jets/Pressure | |
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Arc Load Volts | 31V | 31V | ||
Amps | 150 Amps | 175 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 | |||
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 | Milling Machine or 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 | |
Flame Spray Equipment and Procedure
Flame Spray Information Details | |
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Maximum Surface Texture | Wheel Loader and Wheel Tractor Scraper: Articulated Truck: Wheel Dozer and Integrated Toolcarrier: |
Reason for Spraying | Wear, grooving, or corrosion |
Mating Part Contact Area & Material | Bearing race |
Metco Equipment Type | 6PII by Oerlikon Metco |
Metco Material | Oerlikon Metco 453 |
Finish Thickness | As Required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Device | Lathe or turntable |
Rotation/Traverse Speed | |
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 |
Remarks | Before machining, bolt the caps into place to hold concentricity |
Flame Spray Process (6P) | Procedure | Check List |
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Clean Part | Degrease in hot caustic solution | |
Undercut | To "tru-up" surface | |
Chamfer | If required - |
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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 | 20 mesh aluminum oxide | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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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 |
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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 | |
Rotation Speed of Part | |
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Traverse Rate of Gun | |
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Gun Fixturing Method | Machine mount or hand held | |
Top Coat/Thickness | |
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Finishing Equipment | Lathe or Horizontal Mill | |
Part/Cutter Rotation | |
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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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Alternate Finish Method | Emery cloth for desired finish |