Thermal Spray Procedures for Differential Case - Housing Face & Pinion Thrust Face {3283} Caterpillar


Thermal Spray Procedures for Differential Case - Housing Face & Pinion Thrust Face {3283}

Usage:

769C 01X
Articulated Truck
All
Integrated Toolcarrier
All
Landfill Compactor
816 (S/N: 57U1-UP)
816B (S/N: 15Z1-UP)
816F (S/N: 5FN1-UP; BMR1-UP)
816K (S/N: LT61-UP; SLL1-UP)
826B (S/N: 58U1-UP)
826C (S/N: 87X1-UP)
826G (S/N: 7LN1-UP)
826G Series II (S/N: AYH1-UP)
826K (S/N: 2L31-UP; 2T61-UP)
836G (S/N: BRL1-UP; 7MZ1-UP)
836K (S/N: T6X1-UP; L6Z1-UP)
Off-Highway Truck/Tractor
All
Soil Compactor
815 (S/N: 91P1-UP; 15R1-UP)
815B (S/N: 17Z1-UP)
815F (S/N: BKL1-UP; 1GN1-UP)
815K (S/N: SL91-UP; T1Y1-UP)
825B (S/N: 43N1-UP)
825C (S/N: 86X1-UP)
825G (S/N: 6RN1-UP)
825G Series II (S/N: AXB1-UP)
825K (S/N: 2L91-UP; 2T91-UP)
835 (S/N: 44N1-UP)
Wheel Dozer
814 (S/N: 90P1-UP; 14R1-UP)
814B (S/N: 16Z1-UP)
814F (S/N: BGF1-UP; 9DM1-UP)
814K (S/N: LW41-UP; T1Z1-UP)
824 (S/N: 29G1-UP)
824B (S/N: 36H1-UP)
824C (S/N: 85X1-UP)
824G (S/N: 4SN1-UP)
824G Series II (S/N: AWW1-UP)
824K (S/N: 2T21-UP; 2L41-UP)
834 (S/N: 43E1-UP)
834B (S/N: 7BR1-UP; 92Z1-UP)
834G (S/N: BPC1-UP; 6GZ1-UP)
834K (S/N: TW41-UP; LWY1-UP)
844 (S/N: BBN1-UP; 2KZ1-UP)
844H (S/N: BTW1-UP)
844K (S/N: M4R1-UP; K4Y1-UP)
854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)
854K (S/N: 2211-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)
Wheel Loader
All
Wheel Tractor-Scraper
All

Introduction

Table 1
Revision  Summary of Changes in SEBF2147 
05  Added serial number prefixes.
Updated copyright date to 2018. 
04  Added serial number prefixes.
Updated Introduction. 
03  Updated serial numbers and added confidentiality statement. 
02  Added serial numbers JLX, MXL, SSA, and PCW. 
01  Added referenced media. 

© 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 Table 2.

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 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 2g03072897

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.

Table 2
References 
Media Number  Publication Type & Title 
SEBF9236  Reuse And Salvage Guideline , "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for Reconditioning Components" 
SEBF9238  Reuse And Salvage Guideline , "Fundamentals of Arc Spray for Reconditioning Components" 
SEBF9240  Reuse And Salvage Guideline , "Fundamentals of Flame Spray for Reconditioning Components" 
SEBF8119  Reuse And Salvage Guideline , "Differential Housing Components for Wheel Loaders, Articulated Trucks, Wheel Tractors, Compactors, Integrated Toolcarriers, and Motor Graders
SEB8227  Reuse And Salvage Guideline , "Salvage of Differential Housing Assembly Used on Off-Highway Trucks" 

Part Description

Table 3
Base Metal  Ductile Iron 
Hardness 

Flame Spray Equipment and Procedure

Table 4
Maximum Surface Finish  7.6 to 10.2 Micrometer (300.00 to 400.00 Microinches) 
Reason for Spraying  Wear when load is applied 
Mating Part Contact Area & Material  1/2 Housing/Pinion Gear Bearing inner race 
Metco Equipment Type  6P-II 
Metco Material  452 or 453 
Finished Thickness  As Required 
Finishing Allowance  0.51 to 0.64 mm (0.020 to 0.025 inch) per side 
Spray Angle  70° to 90° 
Substrate Pre-Heat Temperature  66° C (150° F) 
Substrate Temperature During Spraying Not to Exceed  148° C (300° F) 
Auxiliary Cooling  If desired 
Rotation/Traverse Device  Lathe or turntable 
Rotation/Traverse Speed  10.5 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit Blast 
Finishing Method  Machine 
Machining Equipment Type  Lathe 
Recommended Cutter Grade  883 Carboloy or equivalent 

Table 5
Flame Spray Process (6P)  Procedure  Check List 
Clean Part  Degrease in hot caustic solution   
Undercut  To "tru-up" surface   
Chamfer  45°   
Remove Oxide  Clean/strip disc or fiber flap brush   
Mask for Blast  Use metal mask or duct tape   
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  50 mm (2.0 inch)   
Mask for Spray  Anti-bond   
Spray Equipment Type  6P-II   
Auxiliary Cooling  If desired   
Nozzle  6P-C7A-K "K" Nozzle   
Air Capacity/Pressure  6P-3/Cooling Air 140 to 170 kPa (20.0 to 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 inch)   
Rotation Speed of Part (RPM)  75 - 110 RPM (dependent upon dia.)   
Rotation Speed of Part  10.5 SMPM (300.00 SFPM)   
Traverse Rate of Gun  1.7 SMPM (50.000 SFPM)   
Gun Fixturing Method  Machine mount   
Top Coat/Thickness  0.10 to 0.15 mm (0.004 to 0.006 inch) per pass   
Finishing Equipment  Lathe   
Part/Cutter Rotation  5.2 to 6.3 SMPM (150.00 to 180.00 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 polish   

Specifications



Illustration 3g03072898

For dimensional specifications refer to Reuse and Salvage Guideline,, SEBF8119, "Differential Housing Components for Wheel Loaders, Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers". and Reuse and Salvage Guideline,, SEBF8227, "Salvage of Differential Housing Assembly Used on Off-Highway Trucks".

Caterpillar Information System:

Thermal Spray Procedures for Wheel Loaders, Off-Highway Trucks and Tractors, Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers Differential - Support Bearing Journal {0679, 3258, 3284} Thermal Spray Procedures for Wheel Loaders, Off-Highway Trucks and Tractors, Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers Differential - Support Bearing Journal {0679, 3258, 3284}
2012/04/02 A Stainless Steel Braided Hose Is Used for Certain G3500 Engine Fuel Heaters {1380}
Thermal Spray Procedures for Wheel Loader Trunnion {0679, 3268} Thermal Spray Procedures for Wheel Loader Trunnion {0679, 3268}
Thermal Spray Procedures of Differential Carrier Assemblies for Wheel Loader, Wheel Dozer, Compactor, Integrated Toolcarrier, Articulated Truck, and Wheel Tractor Scraper (WTS) {0679, 3284} Thermal Spray Procedures of Differential Carrier Assemblies for Wheel Loader, Wheel Dozer, Compactor, Integrated Toolcarrier, Articulated Truck, and Wheel Tractor Scraper (WTS) {0679, 3284}
Thermal Spray Procedures for Wheel Loader Trunnion Support {0679, 3260, 3268} Thermal Spray Procedures for Wheel Loader Trunnion Support {0679, 3260, 3268}
C175-16 Locomotive Engine Fuel Rail Pressure Is Low
Thermal Spray Procedures for Tyrone Drive Shaft (Pump Gear){0679, 3066, 5073} Thermal Spray Procedures for Tyrone Drive Shaft (Pump Gear){0679, 3066, 5073}
Thermal Spray Procedures for Exhaust Manifold (I.D. ; O.D.){0679, 1059} Thermal Spray Procedures for Exhaust Manifold (I.D. & O.D.){0679, 1059}
Failures of the 305-6843 Guide Spring on Certain Engines{1102, 1121, 1123, 1209} Failures of the 305-6843 Guide Spring on Certain Engines{1102, 1121, 1123, 1209}
2012/03/28 A New Coolant Conditioner Is Now Available {1350, 1352, 1395}
Thermal Spray Procedures for Torque Converter Input Housing {0679, 3101, 3127} Thermal Spray Procedures for Torque Converter Input Housing {0679, 3101, 3127}
2012/03/28 A New Coolant Conditioner Is Now Available {1350, 1352, 1395}
Thermal Spray Procedures for Wheel Loaders, Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers Differential Case - Flange End {0679, 3258, 3284} Thermal Spray Procedures for Wheel Loaders, Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers Differential Case - Flange End {0679, 3258, 3284}
Thermal Spray Procedures for Wheel Loader - Wheel Bearing ID Bore {0679, 4201, 4215} Thermal Spray Procedures for Wheel Loader - Wheel Bearing ID Bore {0679, 4201, 4215}
Thermal Spray Procedures for Wheel Loader Spindle (OD) {3259, 4205, 4215} Thermal Spray Procedures for Wheel Loader Spindle (OD) {3259, 4205, 4215}
Thermal Spray Procedures for Transmission and Torque Converter Yokes {0599, 0679, 3001, 3030, 3101, 3160} Thermal Spray Procedures for Transmission and Torque Converter Yokes {0599, 0679, 3001, 3030, 3101, 3160}
Thermal Spray Procedures for Engine Front Cover{0679, 1150, 1151, 1162} Thermal Spray Procedures for Engine Front Cover{0679, 1150, 1151, 1162}
Thermal Spray Procedures for OHT Rear Spindles {0599, 0679, 4006, 4205} Thermal Spray Procedures for OHT Rear Spindles {0599, 0679, 4006, 4205}
Thermal Spray Procedures for OHT and WTS Rear Wheel - Bearing Bores {0679, 4201} Thermal Spray Procedures for OHT and WTS Rear Wheel - Bearing Bores {0679, 4201}
Thermal Spray Procedures for OHT Front Spindles {0679, 4006, 4205} Thermal Spray Procedures for OHT Front Spindles {0679, 4006, 4205}
2012/03/26 New Software Is Used on Certain C18 Industrial Engines {1901, 1920}
3512C and 3516C Marine Auxiliary Engines Data Link - Test
3516C Generator Set Engines Temperature Sensor (DEF)
Thermal Spray Procedures for OHT and WTS Front Wheel - Bearing Bores {0679, 4006, 4201} Thermal Spray Procedures for OHT and WTS Front Wheel - Bearing Bores {0679, 4006, 4201}
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.