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Pautas de reutilizacin y recuperacin


Thermal Spray Procedures for Engine Front Cover{0679, 1150, 1151, 1162}
Nmero de medio -SEBF2164SEBF2164-02

Fecha de publicacin -12/11/2013

Fecha de actualizacin -12/11/2013

Caterpillar: Confidential Yellow


i05558700

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; 5RM1UP; 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
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.

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

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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.

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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
Table 2
3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series: Aluminum Casting
Base Metal
3500, C27, C32, and C175: Gray Iron
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

Hardness

Arc Spray Equipment and Procedure


Table 3
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

Maximum Surface Finish

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

Clean Part

Degrease in hot aluminum safe cleaner

Undercut

If desired to "tru-up" surface

Chamfer

Check List

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


3406 (4N-3912), 3408 (7C-4843), 3408 and 3412 (6N-5483), ACERT, and C-Series:

Blast Air Pressure

Blast Nozzle to Work Distance

344 kPa (50.0 psi)


3500, C27, C32, and C175:
690 kPa (100.0 psi)
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

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Consumable (Bondcoat)

TAFA 75B

Clamp Pressure

TAFA 75B

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

128 mm (5.0 inch)

128 mm (5.0 inch)

0.038 mm (0.0015 inch)/pass

0.038 mm (0.0015 inch)/pass

Gun to Work Distance (Standoff)


Spray Rate/Bond 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)

Flame Spray Equipment and Procedure


Table 5
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

Maximum Surface Finish

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

Clean Part

Degrease in hot Aluminum safe cleaner

Undercut

If desired to "tru-up" surface

Chamfer

Check List

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

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Metal Spray Equipment Type

Sulzer Metco 6P-II Hand Held Thermo Spray System

Auxiliary Cooling

AJ siphon unit, If desired


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

Nozzle
3500, C27, C32, and C175: 6P-C7A-K "K" Nozzle
6P-3/Cooling Air
140 - 170 kPa (20.0 - 25.0 psi)

Air Capacity/Pressure
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

Specifications

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Illustration 3
3406 (4N-3912)

g03083876

Table 7
3406 Engine - 4N-3912 Front Engine Cover
Dimension
A
B
C
D
E
W

Part No.
190.551 0.038 mm (7.5020 0.0015 inch)
82.601 0.025 mm (3.2520 0.0010 inch)
184.15 0.5 mm (7.250 0.02 inch)
186.093 0.038 mm (7.3260 0.0015 inch)
189.484 0.5 mm (7.46 0.02 inch)
78.816 0.38 mm (3.103 0.015 inch)

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Illustration 4
3408 (7C-4843)

g03337540

Table 8
Series 3408 Engine - 7C-4843 Front Engine Cover
Dimension
A
B
C
D
E
F
W

Part No.
139.950 0.05 mm (5.510 0.002 inch)
120.65 0.025 mm (4.750 0.0010 inch)
101.600 0.025 mm (4.000 0.0010 inch)
120.65 0.025 mm (4.750 0.0010 inch)
186.093 0.038 mm (7.3260 0.0015 inch)
189.48 0.50 mm (7.460 0.020 inch)
63.5 0.38 mm (2.50 0.015 inch)

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Illustration 5
3408 and 3412 (6N-5483)

g03337541

Table 9
3408 and 3412 Engine - 6N-5483 Front Engine Cover
Dimension
A
B
C
D
E
F
W

Part No.
139.950 0.05 mm (5.510 0.002 inch)
120.65 0.025 mm (4.750 0.0010 inch)
101.600 0.025 mm (4.000 0.0010 inch)
120.65 0.025 mm (4.750 0.0010 inch)
186.093 0.038 mm (7.3260 0.0015 inch)
189.48 0.50 mm (7.460 0.020 inch)
63.5 0.38 mm (2.50 0.015 inch)

Ver imagen

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Illustration 6
g03337542
ACERT and C-Series engine front cover: Engine side shown with non-dimensional arrows indicating face to be sprayed.

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Illustration 7
g03337544
ACERT and C-Series engine front cover: Engine side shown with non-dimensional arrows indicating face to be sprayed.

Table 10
ACERT Engine Front Cover
Model

Part No.

C11, C13

238-4755

C-15, 3176C, 3196

155-7965

3176C, 3196

138-2008

Dimension A

Dimension B

85.8 0.3 mm (3.38 0.01 inch)

58.6 0.3 mm (2.31 0.01 inch)

Table 11
ACERT Engine Front Cover
Model

Part No.

Dimension C

128-3883
C7

236-2216
245-3259

C7, C9, C-9

190-5166

C9

236-2215

C9, C-9

245-3261

39.0 0 0.1 mm (1.54 0.01 inch)

7E-6366
3116

132-5242
7E-3864
Table 12

C-Series Engine Front Cover


Model

Part No.

Dimension A

Dimension B

85.8 0.3 mm (3.38 0.01 inch)

58.6 0.3 mm (2.31 0.01 inch)

138-2008
C-10, C-12
159-9259
C-10, C12, C-12, C-15, C-16

155-7965

C11, C13

238-4755
Table 13

C-Series Engine Front Cover


Model

Part No.

Dimension C

128-3883
C7

236-2216
245-3259

C7, C9, C-9

39.0 0.1 mm (1.54 0.01 inch)

190-5166

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C9

236-2215

C9, C-9

245-3261

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Illustration 8
g03337545
ACERT and C-Series engine front cover: Front shown with non-dimensional arrows indicating face to be sprayed.

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Illustration 9
g03337548
ACERT and C-Series engine front cover: Engine side shown with non-dimensional arrows indicating face to be sprayed.

Table 14
ACERT Engine Front Cover
Model

Part No.

Dimension C

187-5420
C15
246-4730
C18, 3456

174-7463
124-6034

3406E, 3456

78.0 0.3 mm (3.07 0.01 inch)

122-2474
3406E

124-6002

3456

172-0285
Table 15

ACERT Engine Front Cover


Model

Part No.

C30, 3408E, 3412E

172-9313

Dimension C
63.5 0.3 mm (2.50 0.01 inch)

Table 16
C-Series Engine Front Cover
Model

Part No.

Dimension D

187-5420
C15
246-4730
C18

78.0 0.3 mm (3.07 0.01 inch)

174-7463

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Illustration 10
3500

Pgina 8 de 12

g03337975

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Illustration 11
3500

g03337977

Table 17
3500 Engine - Front Cover
Part No.

Illus.

8N-8300

101-0832

101-1189

102-8634

Front Cover Thickness


(A)

Dowel Dia.
(B & C)

Location
(D)

Location
(E)

Location
(F)

Location
(G)

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

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)

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

1 or 2 Locations
(P)

1 or 2 Locations
(Q)

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

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

8N-8300
101-0832
101-1189
102-8634

Tolerance is 0.020 mm (0.0008 inch)

Tolerance is 0.05 mm (0.002 inch)

Tolerance is 0.08 mm (0.003 inch)

Tolerance is 0.10 mm (0.004 inch)

Tolerance is 0.25 mm (0.010 inch)

Tolerance is 0.5 mm (0.02 inch)

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Illustration 12
3500

g03337979

Table 19
3524 Engine - Intermediate Engine Front Cover
Part No.

Diameter
(A)

2
Diameters
(C)

Diameter
(B)

2
Diameters
(D)

2
Diameters
(E)

2
Diameters
(F)

Front Cover
Thickness
(G)

136-3216
166-5073

272.00 mm (10.709

inch)3

Tolerance is 0.020 mm (0.0008 inch)

Tolerance is 0.05 mm (0.002 inch)

Tolerance is 0.08 mm (0.003 inch)

Tolerance is 0.10 mm (0.004 inch)

Tolerance is 0.25 mm (0.010 inch)

Tolerance is 0.5 mm (0.02 inch)

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

245.00 mm (9.646 inch)2 511.30 mm (20.130 inch)2


20 mm deep min.

(not shown)

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Illustration 13
C27 and C32

g03337551

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Illustration 14
C27 and C32

g03337552

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Illustration 15
C27 and C32

g03337554

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Illustration 16
C27 and C32

g03337555

Table 20
C27 & C32 Front Engine Covers
Model

Part No.

C27, C32

238-2800

Model

Part No.

C27, C32

238-2800

Dimension A

Dimension B

Dimension C

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)

Dimension D

Dimension E

109.15 0.50 mm (4.297 0.020 inch)

63.50 0.25 mm (2.500 0.010 inch)

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Illustration 17
C27 and C32

Pgina 11 de 12

g03337558

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Illustration 18
C27 and C32

g03337560

Table 21
C27 & C32 Front Engine Covers
Model

Part No.

C32

172-9313

Model

Part No.

C32

172-9313

Dimension F

Dimension G

Dimension H

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)

Dimension I

Dimension J

186.144 0.038 mm (7.3285 0.0015 inch)

63.50 0.38 mm (2.500 0.015 inch)

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Illustration 19
C175 Front View

g03337692

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Illustration 20

g03337694

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Service Information System

Pgina 12 de 12

C175 Rear View

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Illustration 21
C175

g03337697

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Illustration 22
C175

g03337706

Table 22
C175 Engine Cover
Sales Model

Part No.

C175-16

243-5379

C175-16, C175-20

271-4493

C175-16, C175-20

279-0772

Dimension A

Dimension B

Dimension C

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)

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)

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)

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Thu Jul 31 19:31:25 EST 2014

31/07/2014