Proc. Termal Spray Para Cubierta Frontal

Pautas de reutilización y recuperación Pautas de reutilización y recuperación Pautas de reutilización y recuperación Pautas de reutilización y recuperación 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 Engine Front Cover{0679, 1150, 1151, 1162} Thermal Spray Procedures for Engine Front Cover{0679, 1150, 1151, 1162}

Thermal Spray Procedures for Engine Front Cover{0679, 1150, 1151, 1162}

SMCS - 0679; 1150; 1151; 1162

Engine: 3176 Engines 3116 (S/N: 3AF1-UP; 7SF1-UP; 2SG1-UP; 2WG1-UP; 4KG1-UP; 4PG1-UP; 7AG1-UP; 1NJ1-UP; 3RJ1-UP; 7HJ1-UP; 9CJ1-UP; 1SK1-UP; 2BK1-UP; 9GK1-UP; 7JL1-UP; 8WL1-UP; CSM1-UP; 5RM1-UP; 5EN1-UP; 2FR1-UP; 2MR1-UP; 5TS1-UP; 7HS1-UP; 2CW1-UP; 5JZ1-UP; 7TM1-UP) 3116 T (S/N: 9LN1-UP; 9YN1-UP) 3196 (S/N: 1DW1-UP) 3400 3456 All 3500 Engines C-10 All C-9 and C9 All C11 All C12 and C-12 All C13 and C-13 All C15 and C-15 All C16 and C-16 All C175 Engines C18 and C-18 All C27 All C32 All C7 All

Agricultural Tractor: 85D (S/N: 6AR1-UP)

Marine Engine: 3196 MARINE (S/N: 2XR1-UP) C30 MARINE (S/N: CLX1-UP)

Track-Type Tractor: D6M (S/N: 7JS1-UP)

Wheel Loader: 928F (S/N: 4TF1-UP; 6RR1-UP; 98Z1-UP) 950F Series II (S/N: 1CK1-UP) 972G Series II (S/N: 5ED1-UP)

Introduction

© 2013 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 in order 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 in order 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. In order to address an urgent issue, use the following resources in order 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

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.

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.

Número de medio Número de medio Número de medio Número de medio ----SEBF2164SEBF2164SEBF2164SEBF2164----02 02 02 02 Fecha de publicación Fecha de publicación Fecha de publicación Fecha de publicación ----12/11/2013 12/11/2013 12/11/2013 12/11/2013 Fecha de actualización Fecha de actualización Fecha de actualización Fecha de actualización ----12/11/201312/11/201312/11/201312/11/2013

Caterpillar: Confidential YellowCaterpillar: Confidential YellowCaterpillar: Confidential YellowCaterpillar: Confidential Yellow

i05558700

Table 1

Revision Summary of Changes in SEBF2164

02 Added confidentiality statement and updated Praxair TAFA arc spray system.

01 Updated Effectivity

00 Information removed from SERF8473 (Arc Spray Guide CD) and SERF8704 (Flame Spray Guide CD) and formatted for delivery in SIS.

Ver imagen

Illustration 1 g02139237

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.

Página 1 de 12Service Information System

31/07/2014https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&relcalledpage=/sisweb/productsearch/productheaderinfoframeset.jsp

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

Arc Spray Equipment and Procedure

Ver imagen


Table 2

Base Metal 3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: Aluminum Casting 3500, C27, C32, and C175: Gray Iron

Hardness 3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, C-Series, and 3500: N/A C27, C32, and C175: 187 - 241 BHN

Table 3

Maximum Surface Finish

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 4.1 Micrometer (160.00 Microinches) Ra 3500: 3.1 Micrometer (120.00 Microinches) Ra C27, C32, and C175: 3.6 Micrometer (140.00 Microinches) Ra

Reason for Spraying Wear

Mating Part Contact Area & Material Engine Block and seals

Arc Spray Equipment Type Sulzer Metco SmartArc PPG Electric Arc Gun, TAFA 8830 MHU, or TAFA 8835 MHU

Wire TAFA 75B Wire

Finish Thickness As Required

Finishing Allowance 0.51 to 0.64 mm (0.020 to 0.025 inch) 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

Surface Preparation Method Undercut and Grit blast

Machining Method Machine

Recommended Cutting Tool ISCAR DNMG 432TFIC507

Blast Media Recommendation Pressure Type Only (Aluminum Oxide Grit)

Finishing Equipment Type Horizontal or Vertical Boring Machine

Remarks Perform all repair welding prior to metal spray

Table 4

Arc Spray Procedure Check List

Clean Part Degrease in hot aluminum safe cleaner

Undercut If desired to "tru-up" surface

Chamfer 1.5 ± 0.5 mm (0.06 ± 0.02 inch) x 45°

Remove Oxide Use emery cloth or glass bead blaster

Clean Spray Area Commercial degreaser

Mask for Grit Blast Duct Tape, metal shield or rubber

Grit Blast Equipment Pressure type only

Grit Type and Size 20 mesh aluminum oxide

Blast Air Pressure

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 344 kPa (50.0 psi) 3500, C27, C32, and C175: 690 kPa (100.0 psi)

Blast Nozzle to Work Distance 51 to 150 mm (2.0 to 6.0 inch)

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 Sulzer Metco Smart Arc TAFA



Flame Spray Equipment and Procedure

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

Traverse Rate of Gun 12.2 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 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)

Depth of Finish Cut 0.25 mm (0.010 inch)

Table 5

Maximum Surface Finish

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 4.1 Micrometer (160.00 Microinches) Ra 3500: 3.1 Micrometer (120.00 Microinches) Ra C27, C32, and C175: 3.6 Micrometer (140.00 Microinches) Ra

Reason for Spraying Wear

Mating Part Contact Area & Material Engine Block and seals

Sulzer Metco Equipment Type Sulzer Metco 6P-II

Sulzer Metco Material Sulzer Metco 453

Finish Thickness As Required 0.38 mm (0.015 inch)

Finishing Allowance 0.51 to 0.64 mm (0.020 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 If desired

Surface Preparation Method Undercut and Grit blast

Finishing Method Machine

Machining Equipment Type Horizontal or vertical boring machine

Recommended Cutter Grade C-2, 883 Carboloy, or equivalent

Media Recommendation Pressure Type Only (Aluminum Oxide Grit)

Remarks Perform all repair welding prior to metal spray

Table 6

Thermo Spray Process (6P-II) Procedure Check List

Clean Part Degrease in hot Aluminum safe cleaner

Undercut If desired to "tru-up" surface

Chamfer 1.5 ± 0.5 mm (0.06 ± 0.02 inch) x 45°

Remove Oxide Use emery cloth or glass bead blaster

Clean Spray Area Sulzer Metco cleaning solvent or equivalent

Mask for Grit Blast Duct Tape, metal shield or rubber

Grit Blast Equipment Pressure type only

Grit Type and Size 24 mesh aluminum oxide

Blast Air Pressure

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, C-Series, and 3500: 344 kPa (50.0 psi) C27, C32, and C175: 690 kPa (100.0 psi)

Blast Nozzle to Work Distance

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, C-Series, and 3500: 50 mm (2.0 inch) C27, C32, and C175: 50 to 150 mm (2.0 to 6.0 inch)

Remove Blast Mask Remove mask, make sure that surface is clean

Mask for Metal Spray Antibond, Blue layout dye, Duct Tape, metal shield or rubber



Specifications

Metal Spray Equipment Type Sulzer Metco 6P-II Hand Held Thermo Spray System

Auxiliary Cooling AJ siphon unit, If desired

Nozzle 3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 6P-7C-D "D" Nozzle, required 6P-605 Siphon Plug 3500, C27, C32, and C175: 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

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 2.3 kg (5.00 lb) per hour or 38 gr (1.3 oz) per min 3500, C27, C32, and C175: 5.5 kg (12.00 lb) per hour or 90 gr (3.2 oz) per min

Gun to Work Distance

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 216 mm (8.5 inch) 3500, C27, C32, and C175: 230 mm (9.0 inch)

Traverse Rate of Gun 15.24 SMPM (50.000 SFPM)

Gun Fixturing Method Machine mount or hand held

Top Coat/Thickness 0.10 to 0.15 mm (0.004 to 0.006 inch) per pass

Finishing Equipment Milling Machine

Part/Cutter Rotation

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 365.8 SMPM (1200.00 SFPM) 3500, C27, C32, and C175: 91.4 SMPM (300.00 SFPM)

Traverse Speed 0.05 to 0.10 mm (0.002 to 0.004 inch)

Depth of Rough Cut

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 0.25 mm (0.010 inch) 3500, C27, C32, and C175: 0.38 to 0.51 mm (0.015 to 0.020 inch) per side

Depth of Finish Cut

3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: 0.13 mm (0.005 inch) 3500, C27, C32, and C175: 0.25 to 0.38 mm (0.010 to 0.015 inch) per side

Additional Finish Method Emery cloth for desired finish

Ver imagen


3406 (4N-3912)

Table 7

3406 Engine - 4N-3912 Front Engine Cover

Dimension Part No.

A 190.551 ± 0.038 mm (7.5020 ± 0.0015 inch)

B 82.601 ± 0.025 mm (3.2520 ± 0.0010 inch)

C 184.15 ± 0.5 mm (7.250 ± 0.02 inch)

D 186.093 ± 0.038 mm (7.3260 ± 0.0015 inch)

E 189.484 ± 0.5 mm (7.46 ± 0.02 inch)

W 78.816 ± 0.38 mm (3.103 ± 0.015 inch)



Ver imagen


3408 (7C-4843)

Table 8

Series 3408 Engine - 7C-4843 Front Engine Cover

Dimension Part No.

A 139.950 ± 0.05 mm (5.510 ± 0.002 inch)

B 120.65 ± 0.025 mm (4.750 ± 0.0010 inch)

C 101.600 ± 0.025 mm (4.000 ± 0.0010 inch)

D 120.65 ± 0.025 mm (4.750 ± 0.0010 inch)

E 186.093 ± 0.038 mm (7.3260 ± 0.0015 inch)

F 189.48 ± 0.50 mm (7.460 ± 0.020 inch)

W 63.5 ± 0.38 mm (2.50 ± 0.015 inch)

Ver imagen


3408 and 3412 (6N-5483)

Table 9

3408 and 3412 Engine - 6N-5483 Front Engine Cover

Dimension Part No.

A 139.950 ± 0.05 mm (5.510 ± 0.002 inch)

B 120.65 ± 0.025 mm (4.750 ± 0.0010 inch)

C 101.600 ± 0.025 mm (4.000 ± 0.0010 inch)

D 120.65 ± 0.025 mm (4.750 ± 0.0010 inch)

E 186.093 ± 0.038 mm (7.3260 ± 0.0015 inch)

F 189.48 ± 0.50 mm (7.460 ± 0.020 inch)

W 63.5 ± 0.38 mm (2.50 ± 0.015 inch)

Ver imagen




ACERT and C-Series engine front cover: Engine side shown with non-dimensional arrows indicating face to be sprayed.

Ver imagen



Table 10

ACERT Engine Front Cover

Model Part No. Dimension A Dimension B

C11, C13 238-4755

85.8 ± 0.3 mm (3.38 ± 0.01 inch)

58.6 ± 0.3 mm (2.31 ± 0.01 inch)

C-15, 3176C, 3196 155-7965

3176C, 3196 138-2008

Table 11


Model Part No. Dimension C

C7

128-3883

39.0 0 ± 0.1 mm (1.54 ± 0.01 inch)

236-2216

245-3259

C7, C9, C-9 190-5166

C9 236-2215

C9, C-9 245-3261

3116

7E-6366

132-5242

7E-3864

Table 12

C-Series Engine Front Cover

Model Part No. Dimension A Dimension B

C-10, C-12 138-2008

85.8 ± 0.3 mm (3.38 ± 0.01 inch)

58.6 ± 0.3 mm (2.31 ± 0.01 inch)

159-9259

C-10, C12, C-12, C-15, C-16 155-7965

C11, C13 238-4755

Table 13



C7

128-3883

39.0 ± 0.1 mm (1.54 ± 0.01 inch)

236-2216

245-3259

C7, C9, C-9 190-5166



C9 236-2215

C9, C-9 245-3261

Ver imagen


ACERT and C-Series engine front cover: Front shown with non-dimensional arrows indicating face to be sprayed.

Ver imagen



Table 14



C15 187-5420

78.0 ± 0.3 mm (3.07 ± 0.01 inch)

246-4730

C18, 3456 174-7463

3406E, 3456 124-6034

122-2474

3406E 124-6002

3456 172-0285

Table 15



C30, 3408E, 3412E 172-9313 63.5 ± 0.3 mm (2.50 ± 0.01 inch)

Table 16


Model Part No. Dimension D

C15 187-5420

78.0 ± 0.3 mm (3.07 ± 0.01 inch) 246-4730

C18 174-7463

Ver imagen



1 Tolerance is ± 0.020 mm (0.0008 inch)







3500

Ver imagen


3500

Table 17

3500 Engine - Front Cover

Part No. Illus. Front Cover Thickness (A)

Dowel Dia. (B & C)

Location (D)

Location (E)

Location (F)

Location (G)

8N-8300 A

138.00 mm (5.433 inch)5

15.92 mm (0.627 inch)1

226.00 mm (8.898 inch)3

5.00 mm (0.197 inch)3

272.00 mm (10.709 inch)3

369.91 mm (14.563 inch)5

101-0832 B

101-1189 B

102-8634 A

Table 18

3500 Engine - Front Cover

Part No.

2 Locations (H)

Location (I)

3 or 6 Locations (J, K, & L)

Location (M)

2 Locations (N)

Location (O)

1 or 2 Locations (P)

1 or 2 Locations (Q)

8N-8300

30.40 mm (1.197 inch)3

482.40 mm (18.992 inch)3

130.00 mm (5.118 inch)2

198.15 mm (7.801 inch)3

106.64 mm (4.198 inch)3

650.15 mm (25.596 inch)3

245.00 mm (9.646 inch)2 20 mm deep min.


101-0832

101-1189

102-8634

Ver imagen










3500

Table 19

3524 Engine - Intermediate Engine Front Cover

Part No. Diameter (A)

Diameter (B)

2 Diameters (C)

2 Diameters (D)

2 Diameters (E)

2 Diameters (F)

Front Cover Thickness (G)

136-3216 272.00 mm (10.709 inch)3

360.00 mm (14.173 inch)4

187.00mm (7.362 inch)2

220.00 mm (8.661 inch)5

100.00 mm (3.937 inch)2


511.30 mm (20.130 inch)2 (not shown)

166-5073

Ver imagen


C27 and C32

Ver imagen




C27 and C32

Ver imagen


C27 and C32

Ver imagen


C27 and C32

Table 20

C27 & C32 Front Engine Covers

Model Part No. Dimension A Dimension B Dimension C

C27, C32 238-2800 133.00 ± 0.05 mm (5.236 ± 0.002 inch)

120.650 ± 0.025 mm (4.7500 ± 0.0010 inch)

186.144 ± 0.038 mm (7.3285 ± 0.0015 inch)

Model Part No. Dimension D Dimension E

C27, C32 238-2800 109.15 ± 0.50 mm (4.297 ± 0.020 inch)

63.50 ± 0.25 mm (2.500 ± 0.010 inch)

Ver imagen




C27 and C32

Ver imagen


C27 and C32

Table 21

C27 & C32 Front Engine Covers

Model Part No. Dimension F Dimension G Dimension H

C32 172-9313 247.5 ± 1.0 mm (9.74 ± 0.04 inch)

120.650 ± 0.025 mm (4.7500 ± 0.0010 inch)

157.95 ± 0.05 mm (6.218 ± 0.002 inch)

Model Part No. Dimension I Dimension J

C32 172-9313 186.144 ± 0.038 mm (7.3285 ± 0.0015 inch)

63.50 ± 0.38 mm (2.500 ± 0.015 inch)

Ver imagen


C175 Front View

Ver imagen




C175 Rear View

Ver imagen


C175

Ver imagen


C175

Table 22

C175 Engine Cover

Sales Model Part No. Dimension A Dimension B Dimension C

C175-16 243-5379 139.00 ± 0.25 mm (5.472 ± 0.010 inch)

130.00 ± 0.05 mm (5.118 ± 0.002 inch)

315.00 ± 0.05 mm (12.402 ± 0.002 inch)

C175-16, C175-20 271-4493 139.00 ± 0.25 mm (5.472 ± 0.010 inch)

130.00 ± 0.05 mm (5.118 ± 0.002 inch)

315.00 ± 0.05 mm (12.402 ± 0.002 inch)

C175-16, C175-20 279-0772 139.00 ± 0.25 mm (5.472 ± 0.010 inch)

130.00 ± 0.05 mm (5.118 ± 0.002 inch)

315.00 ± 0.05 mm (12.402 ± 0.002 inch)

Copyright 1993 - 2014 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS.

Thu Jul 31 19:31:25 EST 2014



Proc. Termal Spray Para Cubierta Frontal

Documents

Transcript of Proc. Termal Spray Para Cubierta Frontal