Thermal Spray Procedures for OHT and WTS Rear Wheel - Bearing Bores {0679, 4201} Caterpillar


Thermal Spray Procedures for OHT and WTS Rear Wheel - Bearing Bores {0679, 4201}

Usage:

769C 01X
Off-Highway Truck/Tractor
All
Wheel Tractor-Scraper
All

Introduction

Table 1
Revision  Summary of Changes in SEBF2168 
05  Added 3 part numbers. 
04  Added two part numbers. 
03  Changed supplier name from Sulzer Metco to Oerlikon Metco. 

© 2017 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 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 2g03086056

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
OHT Rear Wheel - Bearing Bores 
Base Metal  1026 Mod or Ductile iron 
Hardness  156-217 BHN 

Table 3
WTS Rear Wheel - Bearing Bores 
Base Metal  Ductile Iron 
Hardness  28-34 Rc 

Arc Spray Equipment and Procedure

Table 4
Maximum Surface Finish  3.5 Micrometer (140.00 Microinch) 
Reason for Spraying  Wear or grooving 
Mating Part Contact Area & Material  Bearing 
Arc Spray Equipment Type  Smart Arc 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  92.0 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit blast 
Equipment Required  Turn Vertical Lathe 
Recommended Cutting Tool  ISCAR DNMG 432TFIC507 
Blast Media Recommendation  Pressure Type Only (Aluminum Oxide Grit) 

Table 5
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 inch) x 45°   
Remove Oxide  Use fiber flap brush or Clean/strip disc   
Clean Spray Area  Commercial degreaser   
Mask for Grit Blaster  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 mm to 150 mm (2.0 inch to 6.0 inch)   
Remove Blast Mask  Remove mask material, make sure that surface is clean   
Mask for Metal Spray  Antibond 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 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  92.0 SMPM (300.00 SFPM)   
  Traverse Rate of Gun  11.0 SMPM (40.00 SFPM)   
Gun Fixturing Method  Machine mount or hand held   
Finishing Equipment  Milling Machine   
Part/Cutter Rotation Roughing  50.0 SMPM (150.00 SFPM)   
Part/Cutter Rotation Finishing  75.0 SMPM (250.00 SFPM)   
Coolant  Oil base 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

Table 6
Maximum Surface Finish  3.6 Micrometer (140.00 Microinch) 
Reason for Spraying  Wear or grooving 
Mating Part Contact Area & Material  Bearing 
Metco Equipment Type  6P-II byOerlikon Metco 
Metco Material  Metco 453 
Finish Thickness  As Required 
Finishing Allowance  0.51 mm to 0.64 mm (0.020 inch 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  Filtered shop air 
Rotation/Traverse Device  Lathe or headstock/tailstock arrangement, rotary turntable 
Rotation/Traverse Speed  91.4 SMPM (300.00 SFPM) 
Surface Preparation Method  Undercut and Grit Blast if necessary 
Finishing Method  Machine 
Machining Equipment Type  Vertical Lathe 
Recommended Cutter Grade  C-2, 883 Carboloy or equivalent 

Table 7
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 or 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  Aluminum Oxide 20 mesh   
Blast Air Pressure  690 kPa (100.0 psi)   
Blast Nozzle to Work Distance  51 mm to 150 mm (2.0 inch 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 (12.00 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)  RPM varies depending on diameter   
Rotation Speed Of Part (SFPM)  91.4 SMPM (300.00 SFPM)   
Traverse Rate of Gun (SFPM)  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 inch to 0.006 inch) per pass   
Finishing Equipment  Lathe or Horizontal Mill   
Part/Cutter Rotation (SFPM)  91.4 SMPM (300.00 SFPM)   
Traverse Speed  0.05 mm to 0.10 mm (0.002 inch to 0.004 inch) per revolution   
Depth of Rough Cut  0.38 mm to 0.51 mm (0.015 inch to 0.020 inch) per side   
Depth of Finish Cut  0.25 mm to 0.38 mm (0.010 inch to 0.015 inch) per side   
Additional Finish Method  Emery cloth for desired finish   

Specifications



Illustration 3g03086136

Table 8
OHT Rear Wheel - Bearing Bores 
Part No.  Dimension A  Dimension B 
8X-1047  317.449 ± 0.038 mm (12.4980 ± 0.0015 inch)  317.449 ± 0.038 mm (12.4980 ± 0.0015 inch) 
5D-6212 
6D-0442 
6D-7471 
2G-5727 
308-3195 
308-3168 
8D-4934  346.012 ± 0.038 mm (13.6225 ± 0.0010 inch)  380.937 ± 0.038 mm (14.9975 ± 0.0015 inch) 
8X-9576 
2G-5003  346.012 ± 0.038 mm (13.6225 ± 0.0015 inch)
8D-3197 
271-9274 
2G-5347  380.937 ± 0.038 mm (14.9975 ± 0.0015 inch)  380.937 ± 0.038 mm (14.9975 ± 0.0015 inch) 
2G-5401  384.112 ± 0.038 mm (15.1225 ± 0.0015 inch)
6G-1366  380.936 ± 0.038 mm (14.9974 ± 0.0015 inch)  384.112 ± 0.038 mm (15.1225 ± 0.0015 inch) 
6G-6563  380.872 ± 0.038 mm (14.9950 ± 0.0015 inch)  384.048 ± 0.038 mm (15.1200 ± 0.0015 inch) 
216-2624  406.272 ± 0.026 mm (15.9949 ± 0.0010 inch)  384.048 ± 0.026 mm (15.1200 ± 0.0010 inch) 
119-9065 
310-6094 
2G-5294  380.937 ± 0.038 mm (14.9975 ± 0.0015 inch)  380.937 ± 0.038 mm (14.9975 ± 0.0015 inch) 
6G-3658 
285-5297  406.272 ± 0.026 mm (15.9949 ± 0.0010 inch)  384.048 ± 0.038 mm (15.1200 ± 0.0015 inch) 
2A-6581  488.734 ± 0.038 mm (19.2414 ± 0.0015 inch)  447.485 ± 0.038 mm (17.6175 ± 0.0015 inch) 
4C-1892  488.734 ± 0.038 mm (19.2414 ± 0.0015 inch)  447.485 ± 0.038 mm (17.6175 ± 0.0015 inch) 
213-3732  507.796 ± 0.026 mm (19.9919 ± 0.0010 inch)  507.796 ± 0.026 mm (19.9919 ± 0.0010 inch) 
5T-9539  488.887 ± 0.038 mm (19.2475 ± 0.0015 inch)  447.612 ± 0.038 mm (17.6175 ± 0.0015 inch) 
8X-2633  447.485 ± 0.038 mm (17.6175 ± 0.0015 inch)
139-9584  507.796 ± 0.025 mm (19.9919 ± 0.0010 inch)  507.796 ± 0.025 mm (19.9919 ± 0.0010 inch) 
5T-5842  546.051 ± 0.025 mm (21.4980 ± 0.0010 inch)  546.051 ± 0.025 mm (21.4980 ± 0.0010 inch) 
8X-2636  545.871 ± 0.025 mm (21.4909 ± 0.0010 inch)  545.871 ± 0.025 mm (21.4909 ± 0.0010 inch) 
125-0061 
142-5946  590.322 ± 0.025 mm (23.2410 ± 0.0010 inch)  590.322 ± 0.025 mm (23.2410 ± 0.0010 inch) 
214-1644  590.322 ± 0.026 mm (23.2410 ± 0.0010 inch)  590.322 ± 0.026 mm (23.2410 ± 0.0010 inch) 
102-0313 
8X-1019 
132-4515 
135-2555 
270-4457  641.100 ± 0.025 mm (25.2401 ± 0.0010 inch)  641.100 ± 0.025 mm (25.2401 ± 0.0010 inch) 
139-7619  812.470 ± 0.025 mm (31.9869 ± 0.0010 inch)  812.470 ± 0.025 mm (31.9869 ± 0.0010 inch) 
210-5709 

Table 9
WTS Rear Wheel - Bearing Bores 
Part No.  Dimension A  Dimension B 
110-7923  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch)  317.419 ± 0.050 mm (12.4968 ± 0.0020 inch) 
110-7928 
153-6458  190.423 ± 0.025 mm (7.5000 ± 0.0010 inch)  193.598 ± 0.025 mm (7.6220 ± 0.0010 inch) 
1V-1687  180.975 ± 0.025 mm (7.1250 ± 0.0010 inch)  193.612 ± 0.035 mm (7.6225 ± 0.0014 inch) 
2G-8986  190.429 ± 0.050 mm (7.4972 ± 0.0020 inch)  190.429 ± 0.050 mm (7.4972 ± 0.0020 inch) 
2G-9056  259.893 ± 0.050 mm (10.2320 ± 0.0020 inch)  239.903 ± 0.050 mm (9.4450 ± 0.0020 inch) 
2G-9057  190.429 ± 0.050 mm (7.4972 ± 0.0020 inch)  190.429 ± 0.050 mm (7.4972 ± 0.0020 inch) 
2G-9059  259.893 ± 0.050 mm (10.2320 ± 0.0020 inch)  239.903 ± 0.050 mm (9.4450 ± 0.0020 inch) 
2G-9066 
2T-0491  161.912 ± 0.013 mm (6.3745 ± 0.0005 inch)  133.312 ± 0.013 mm (5.2485 ± 0.0005 inch) 
2T-0675  199.970 ± 0.020 mm (7.8728 ± 0.0007 inch)  177.750 ± 0.020 mm (6.9988 ± 0.0007 inch) 
2T-1940  190.450 ± 0.035 mm (7.4980 ± 0.0014 inch)  177.768 ± 0.020 mm (6.9987 ± 0.0007 inch) 
2T-1949  161.912 ± 0.013 mm (6.3745 ± 0.0005 inch)  133.312 ± 0.013 mm (5.2485 ± 0.0005 inch) 
3D-6205  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch)  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch) 
4D-4569  346.011 ± 0.038 mm (13.6225 ± 0.0015 inch)  346.011 ± 0.038 mm (13.6225 ± 0.0015 inch) 
4D-7612  314.274 ± 0.038 mm (12.3730 ± 0.0015 inch)  282.524 ± 0.038 mm (11.1230 ± 0.0015 inch) 
4J-0875 
4J-7690  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch)  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch) 
5D-5456  266.649 ± 0.038 mm (10.4980 ± 0.0015 inch)  247.599 ± 0.038 mm (9.7480 ± 0.0015 inch) 
5T-5050  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch)  317.419 ± 0.050 mm (12.4968 ± 0.0020 inch) 
6G-1316  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch)  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch) 
6G-1317  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch)  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch) 
6G-1804  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch)  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch) 
5V-4061  190.437 ± 0.035 mm (7.4975 ± 0.0014 inch)  193.612 ± 0.036 mm (7.6225 ± 0.0014 inch) 
6G-0931  190.430 ± 0.050 mm (7.4972 ± 0.0020 inch)  190.430 ± 0.050 mm (7.4972 ± 0.0020 inch) 
6G-0958 
6G-1315  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch)  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch) 
7J-5380  161.912 ± 0.013 mm (6.3745 ± 0.0005 inch)  133.312 ± 0.013 mm (5.2485 ± 0.0005 inch) 
7K-1137  180.975 ± 0.025 mm (7.1250 ± 0.0010 inch)  193.624 ± 0.025 mm (7.6230 ± 0.0010 inch) 
8D-2088  259.913 ± 0.038 mm (10.2328 ± 0.0015 inch)  259.918 ± 0.038 mm (9.4456 ± 0.0015 inch) 
8D-2228  314.244 ± 0.050 mm (12.3718 ± 0.0020 inch)  282.494 ± 0.050 mm (11.1218 ± 0.0020 inch) 
8D-2231  314.274 ± 0.038 mm (12.3730 ± 0.0015 inch)  282.524 ± 0.038 mm (11.1230 ± 0.0015 inch) 
8D-2266  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch)  292.036 ± 0.038 mm (11.4975 ± 0.0015 inch) 
8D-2270 
8D-8529  190.450 ± 0.038 mm (7.4980 ± 0.0015 inch)  190.450 ± 0.038 mm (7.4980 ± 0.0015 inch) 
8D-8536  259.913 ± 0.038 mm (10.2328 ± 0.0015 inch)  239.918 ± 0.038 mm (9.4456 ± 0.0015 inch) 
8D-8547 
8I-1846  190.423 ± 0.025 mm (7.5000 ± 0.0010 inch)  177.724 ± 0.025 mm (6.9970 ± 0.0010 inch) 
8K-6295  180.975 ± 0.025 mm (7.1250 ± 0.0010 inch)  193.624 ± 0.025 mm (7.6230 ± 0.0010 inch) 
8R-4087  190.437 ± 0.035 mm (7.4975 ± 0.0014 inch)  193.612 ± 0.036 mm (7.6225 ± 0.0014 inch) 
8V-6398 
8W-9331  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch)  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch) 
8W-9804  259.893 ± 0.050 mm (10.2320 ± 0.0020 inch)  239.903 ± 0.050 mm (9.4450 ± 0.0020 inch) 
8W-9805  239.903 ± 0.050 mm (9.4450 ± 0.0020 inch)
8W-9812  259.890 ± 0.050 mm (10.2319 ± 0.0020 inch)  239.900 ± 0.050 mm (9.4449 ± 0.0020 inch) 
8W-9955 
8W-9983  190.430 ± 0.050 mm (7.4972 ± 0.0020 inch)  190.430 ± 0.050 mm (7.4972 ± 0.0020 inch) 
8X-0401  346.000 ± 0.050 mm (13.6220 ± 0.0020 inch)  317.419 ± 0.050 mm (12.4968 ± 0.0020 inch) 
8X-0402 
9D-0115  314.244 ± 0.050 mm (12.3718 ± 0.0020 inch)  282.494 ± 0.050 mm (11.1218 ± 0.0020 inch) 
9D-0133  314.243 ± 0.050 mm (12.3718 ± 0.0020 inch)  292.019 ± 0.050 mm (11.4968 ± 0.0020 inch) 
303-3116  259.89 ± 0.05 mm (10.2319 ± 0.002 inch)  239.9 ± 0.05 mm (9.4449 ± 0.002 inch) 
371-9592  314.275 ± 0.04 mm (12.3730 ± 0.002 inch)  336.5 ± 0.04 mm (13.2480 ± 0.002 inch) 
371-9567  292.05 ± 0.04 mm (11.4980 ± 0.002 inch)  292.05 ± 0.04 mm (11.4980 ± 0.002 inch) 

Caterpillar Information System:

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