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Pautas de reutilización y recuperación

General Salvage and Reconditioning Techniques
Número de medio -SEBF8148-02 Fecha de publicación -15/09/2004 Fecha de actualización -15/09/2004
SEBF81480001

SMCS - 1000; 7000
CATERPILLAR®
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
Table 1
Summary of Revisions
Page Description
10 Took out Metal Stitch Procedure and
added new LOCK-N-STITCH®.
Procedure
12 Added section on LOCK-N-STITCH®.
Thread Repair Inserts
All Revised format.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 30/06/2006
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Introduction
This guideline enables dealers and their customers to benefit from cost reductions made possible through
an established parts reusability and salvage program. Every effort has been made to provide the most
current and relevant information known to Caterpillar Inc. Since the Company makes ongoing changes
and improvements to its products, this guideline must be used with the latest technical information
available from Caterpillar to ensure such changes and improvements are incorporated where applicable.
For questions or additional information concerning this guideline, contact Caterpillar Dealer Service
Operations (309) 675-6304.
Summary
Caterpillar has issued many Guidelines for Reusable Parts and Salvage Operations, Special Instructions
and various other publications for the salvage, modification and repair of specific components. This
guideline describes:
• Various repair and salvage methods.
• When and how they can be applied to Caterpillar components not covered by other publications or
specific guidelines.
• Several methods of detecting cracks before and after parts are repaired or salvaged.
Some components, due to application, heat treatment, or metallurgy, are unacceptable for salvage or
reconditioning and are not covered by this or any other publication.
Important Safety Information
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.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result i
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 warning 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" and followed by a "Signal Word" such as
"WARNING" as shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE"' labels on the product and in this
publication.
NOTICE
Notice labels in this publication identify

operations that may cause product damage.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all-inclusive. If a tool, procedure, work
method or operating technique that is not specifically recommended by Caterpillar is used, you must
satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be
damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you
choose.
The information, specifications, and illustrations in this publication are on the basis of information that w
available at the time that the publication was written. The specifications, torque, pressures, measurement
adjustments, illustrations, and other items can change at any time. These changes can affect the service
that is given to the product. Contact your Caterpillar dealer to obtain complete information and the most
current information available before you start any job.
Do not operate or work on this product until you

have read and understood the operation,
lubrication, maintenance, and repair information.
Failure to follow the instructions for operation,
lubrication, maintenance, or repair of this product
could result in injury or death.
Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact
skin.
When you check for a leak, use a board or

cardboard. Leaking fluid that is under pressure
can penetrate body tissue. Fluid penetration can
cause serious injury and possible death. A pinhole
leak can cause sever injury. If fluid is injected
into your skin, you must obtain treatment
immediately. Seek treatment from a doctor that is
familiar with this type of injury.
Types Of Salvage Procedures
1. Machine and sleeve to standard size.

2. Machine undersize/oversize.
3. Weld and machine to standard size.
4. Weld.
5. Thermal spray and machine to standard size.
6. Composite fill.
7. Machine, chrome plate and machine to standard size.
8. Machine and nickel-plate to standard size.
9. LOCK-N-STITCH® Method for Metal Stitching.
10. Anaerobic materials.
11. LOCK-N-STITCH® Thread Repair Inserts.
12. Standard Threaded inserts.
Typical Applications
Table 2
Table 2.
Typical Applications of Salvage Procedures
Type of Salvage
Type of Part Material 1 2 3 4 5 6 7 8 9 10 11 12
Bearing Inner Race Mild X X X X X X
Support Steel
Bearing Outer Race Cast Iron X X X X X X
Support
Worn Dowel Hole Cast Iron X X
Worn Seal Ring Cast Iron X X X X X X
Bore
Cracked Hsg. Cast Iron X X
(Nonstructural)
Cracked Housing X X
Damaged Tapped Various X X X X
Hole
Selecting Procedure
As Table 2 indicates, there may be more than one acceptable salvage method that best fits your machine
shop's equipment. Sometimes, characteristics of a specific "Type Of Part" may prevent the use of some
options. For example, wear in a seal ring bore may exceed the maximum acceptable diameter, thereby
eliminating the "machine undersize/oversize" option. Or, it may just be necessary to remove a small wear
step from the ring bore.
Note: Some of the procedures refer to the term "Machine". Whenever there is a machinery operation, it i
important to use good machine shop practices concerning feeds, speeds, machine tool size and condition,
cutting tool type and condition, cutting fluids, etc. to insure the successful salvaging of a part. (Refer to
section, "Machine Shop Practices".)
General Salvage Procedures
1. Machine and Sleeve to Standard Size
Procedure Description
This salvage procedure consists of machining a shaft or cylindrical bore undersize or oversize,
respectively, and installing a sleeve made of a material compatible with the base part.
Application Limitations
Do not install simple, cylindrical sleeves if one end of the sleeve will be subjected to hydraulic pressures
other thrust loads that would tend to push the sleeve out. Such applications require positive retention of th
sleeve by pins, weld or set screws. Other methods include incorporating a flange on the sleeve, or either a
shoulder in the bore or on the OD of the piece being repaired (See Illustrations 1-4).
This procedure is not recommended for highly stressed/loaded bores such as loader frames or ripper bore
Illustration 1
Simple cylindrical sleeve
Illustration 2
Sleeve against a shoulder in the bore
Illustration 3
Sleeve with a flange
Illustration 4
Sleeve against a shoulder on OD of bore.
Sleeve Material
Whenever possible, material for the sleeves should be similar to the base material. This will minimize th
possibility of the sleeve loosening during operation because of different expansion rates. Similar materia
will also minimize the possibility of corrosion induced by electrolysis. Of lesser concern, but still worthy
of consideration, is the need to maintain compatibility between mating surfaces to avoid problems such a
galling or excessive wear.
Expansion Fit
An "expansion fit" sleeve is one that requires the chilling of the sleeve, which reduces the OD of the
sleeve, in order for it to be installed in a bore. As the installed sleeve reaches ambient temperature it
expands into the bore creating the desired fit. Chilling may be accomplished with a freezer, do not go
below –55°C (-67°F).
Table 3 provides the "rules of thumb" to determine the amount of chilling necessary for various amounts
interference between parts.
Note: "Shrinkage" is units per unit of diameter. For example, dry ice will shrink a 25 mm (1.0 inch)
diameter steel sleeve at room temperature (21°C or 70°F) approximately 0.028 mm (0.0011 inch). A 255
mm (10.0 inch) diameter sleeve will shrink approximately 0.28 mm (0.011 inch).
Table 3
Table 3
Expansion Fit Shrink Rate
Material Shrink Shrink
(mm / °C) (inch / °F)
Aluminum 0.0000191 0.0000106
Cast Iron 0.0000077 0.0000043
Copper 0.0000149 0.0000083
Steel 0.0000092 0.0000051
to to
0.0000137 0.0000076
Shrink Fit
A "shrink fit" sleeve is one that requires the heating of the sleeve, which increases the ID, in order to inst
it onto another part. As the sleeve returns to ambient temperature, the sleeve shrinks to the correct fit.
Heating may be done with an oil bath or induction type bearing heater, or an oven. The use of a torch is n
recommended because of inherent uneven heating, and localized overheating problems.
Use Table 4 to determine the amount of heating necessary for various amounts of interference between
parts.
Note: Expansion is units per unit of diameter. For example, a 25 mm (1.0 inch) diameter steel sleeve at
room temperature (21°C or 70°F) will expand approximately 0.0036 mm (0.0014 inch) when heated to
150°C (300°F). [A 255 mm (10.0 inch) diameter sleeve will expand approximately 0.37 mm (0.015 inch)
Table 4
Table 4
Shrink Fit Expansion Rate
Material Expansion Expansion
(mm / °C) (inch / °F)
Aluminum 0.0000224 0.0000124
Cast Iron 0.0000119 0.0000066
Copper 0.0000162 0.0000090
Steel 0.0000113 0.0000063
Press Fit
A press fit is the interference between the bearing OD and the housing bore ID. This type of fit is intende
to determine the accurate location of the mating parts, and for parts requiring rigidity and alignment with
no special requirement for bore pressure. In this type of fit, the sleeve/bearing should be pressed into the
bore not driven in.
Sleeve Retention
Simple Cylindrical ID Sleeve
a. Be sure that the sleeves and bores are as clean and dry as possible.
b. Apply 6V-1541 Quick Cure Primer to the sleeve OD and bore.
c. Apply a thin film of 9S-3265 Retaining Compound to the sleeve OD.
d. Press the sleeve into the bore (chill the sleeve according to the topic, "Expansion Fit".
Simple Cylindrical OD Sleeve
a. Be sure that the sleeve ID and shaft OD are as clean and dry as possible.
b. Apply 6V-1541 Quick Cure Primer to the sleeve ID and shaft OD.
c. Apply a thin film of 9S-3265 Retaining compound to the shaft OD.
d. Press the sleeve onto the shaft (heat the sleeve according to the topic, "Shrink Fit". Do not exceed a
maximum of 150 °C (300 °F).
Other Sleeve Design Requirements
Outside corners of sleeves and shafts must have a radius or chamfer at least as large as the radius or
chamfer on the mating inside corner. Failure to provide such chamfers or radii can result in a sleeve that
loosens, and ultimately fails during use. Chamfers or radii also permit the sleeve to be pressed into or on
the part being salvaged without shearing material from the bore or shaft. Lastly, chamfers permit the
repaired part to be assembled more easily.
a. Sleeve bearings pressed into heavy section steel or cast iron housings.
b. Bores with rotating shafts.
c. Repair of reaction dowel holes in transmission clutch housings.
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2. Machine Undersize/Oversize
This salvage procedure consists of machining a surface to remove worn or damaged areas and restoring th
original surface finish, but with different finished dimensions. Either the change in size must not affect th
function of the part, or a special service part must be available or fabricated to compensate for the materia
removed during the salvage operation.
Applications Limitations
Seal ring bores and piston ring bores.
Not all piston/seal ring applications have oversize/undersize rings available. A small amount of material
can be removed from the contact face in order to remove wear grooves or steps. It is important not to
exceed the general wear limits listed here.
a. Engine cylinder (liner) bores: Refer to the appropriate Guideline For Reusable Parts for permissible
wear.
b. Transmission clutch piston bores (for cast iron seal rings).
c. Transmission clutch piston bores (for Teflon seal rings).
d. Transmission and torque converter housings, cages, and manifolds.
e. Crankshafts.
f. Camshafts.
g. Clutch plates.
h. Transmission pistons.
i. Hydraulic pump parts.
j. Bores and shafts that serve as bearing races. Engineering design does not permit the removal of wear
steps.
3. Weld and Cut To Standard Size
This salvage procedure consists of building up worn or damaged surfaces or areas with weld, and machin
the weld back to original dimensions. (See Special Instruction SEHS8919 for typical cast iron welding
procedures.)
a. Cast iron and steel require a specific weld. See SEHS8919 for specific procedure.
b. Potential for heat-induced warpage must be considered.
c. Potential for annealing or cracking heat-treated shafts.
a. Seal wear areas.
b. Bearing support (shafts and bores).
c. Worn dowel holes.
d. Loader frames and ripper frames.
e. Track roller frames.
f. Hydraulic cylinder eyes.
4. Weld
This salvage procedure consists of building up worn or damaged surfaces or areas with weld. The noncrit
nature of the "finished dimensions" given for areas of some parts do not require post-weld machining of t
weld deposit (other than dressing with a hand grinder or rotary file).
See Special Instruction SEHS8919 for typical cast iron welding procedures.
a. Cast iron and steel require a specific weld. See SEHS8919 for the specific procedure.
b. Potential for heat-induced warpage must be considered.
a. Weldable areas damaged by external forces.
b. Track rollers, links and idlers.
c. Bucket edges.
d. Crankcase guards (belly pans).
5. Thermal Spray and Machine to Standard Size Procedure Description
This salvage procedure consists of machining the worn or damaged surface, then build up the surface wit
thermal spray, and machining to original dimensions. Thermal spray is not a welding process, but a
bonding process by using heat and high velocity particles, so it does not add any structural strength.
Correctly applied thermal spray will not affect the heat treat of the base material. Thermal spray at
Caterpillar consists of the following processes:
a. Flame Spray is the basic thermal spray process for restoring a surface and is limited to a lower bond
strength and hardness of the coating.
b. Arc Spray is a step up from Flame Spray in the aspect of higher bond strength and the ability to apply
a harder wear resistant coating.
c. High Velocity Oxygen Fuel (HVOF) is the thermal spray process that provides the highest bond
strength and hardest coating. This process is used to replace chrome plating on cylinder rods.
For complete information regarding thermal spray, contact Caterpillar Dealer Service Operations at 309-
675-5434.
a. No impact or point-loading applications currently recommended.
b. Quality of coating is very dependent upon process control during every step of the salvage procedure
c. No bending applications.
a. Seal wear areas.
c. Worn dowel holes.
d. Bores in housings.
e. Cylinder rods and struts (HVOF).
6. Composite Fill
This salvage procedure consists of building up worn or damaged surfaces or areas with nonmetallic
composites. See Special Instruction, REHS2133, for typical repair procedures using composite materials.
a. No impact or point-loading applications.
b. Quality of coating is very dependent upon process control.
c. Operational temperature limitations.
a. Engine cylinder blocks.
b. Porosity.
c. Erosion.
d. Crack repair (nonstructural).
8. Machine, Chrome Plate and Machine To Standard Size
Chrome plating is a very specialized process. Actual plating instructions are beyond the scope of this
publication.
This salvage procedure consists of machining worn or damaged outer surfaces undersize, chrome plating
and finish-grinding the surfaces to original dimensions. Although more difficult to do, inside surfaces are
sometimes machined oversize, plated and ground to original dimensions. Chrome plated parts may need t
be put into a 150°C (300°F) oven for three hours to prevent cracking (hydrogen-embrittlement) of the par
The baking must be started within an hour after removal from the plating tank.
Plating thickness can range from 0.005 mm (0.0002 inch) to more than 0.5 mm (0.02 inch), depending on
the application.
c. No bending applications.
a. Seal wear areas.
c. Transmission and hydraulic control valve spools.
d. Hydraulic cylinder rods.
e. Bucket and loader pins.
9. Cut and Nickel Plate To Standard Size
Electroless nickel plating is a very specialized process. Actual plating instructions are beyond the scope o
this publication.
Electroless nickel plating, a chemical process, is less common than chrome electroplating, but has certain
advantages over chrome. The most important advantage is the ability to plate to exact size and not require
a post-plating grinding operation.
Another advantage of electroless nickel plating is the uniformity of the build-up. Corners and unmasked
inside diameters will plate at the same rate as the outside surfaces, whereas chrome builds up on sharp
edges at a higher rate than on flat, outside surfaces, and inside diameters build up at a slower rate than
outside diameters.
The basic salvage procedure consists of machining worn or damaged outer surfaces undersize and plating
the surfaces to original dimensions. Although less commonly done (but easier to do than chrome plating)
inside surfaces are machined oversize and plated to original dimensions. Care must be taken during
premachining, as the surface finish of the premachining determines the final surface finish.
c. Build-up thickness is limited to approximately 0.13 to 0.18 mm

(0.005 to 0.007 inch).
d. Plating build-up is very slow, approximately 0.013 mm (0.0005 inch) per hour.
e. As plated hardness is Rockwell C 48-52. Hardness after a low temperature (190°C or 375°F) heat
treatment goes up to about Rockwell C 58. Maximum hardness of Rockwell C 65 is reached with a high
temperature (370°C or 700°F) heat treatment. Sometimes light polishing may be required after the high
temperature heat treatment.
a. Seal wear areas.
c. Transmission and hydraulic control valve spools.
10. Lock-N-Stitch Procedure for Metal Stitching
Metal stitching is a simple concept where the crack is removed and replaced with an overlapping series o
stitching pins, with Locks installed at intervals along the length of the repair for added strength. The
following are the four steps of metal stitching (See Illustration 5):
1. Drilling the lock hole pattern
2. Installing the Lock
3. Start installing stitching pins
4. Completed repair is ground flush
Illustration 5
Note: For further information on metal stitching refer to SEBF8882 Using Lock-N-Stitch Procedures for
Casting Repair.
Varies depending on parts to repair.
a. Cracked engine block or heads
b. Transmission cases.
c. Oil pans
11. Anaerobic Materials
This salvage procedure uses polymers that are self-curing without air to compensate for marginally
excessive wear in press fit joints. Materials in this category are found in the
9S-3262 Sealant Repair Kit.
a. Operational temperature limitations.
b. Surface cleanliness is important for maximum success.
a. 9S-3265 Retaining Compound (Usable up to 200°C or 400°F). Restores fit to worn parts such as: Key
and keyways, pins, splines, gears, pulleys.
b. 7M-7456 Bearing Mount (Usable up to 150°C or 300°F). Restores fit to worn parts, and aids the fit fo
new parts such as: ball and roller bearing races, cups and cones, bushings.
12. Lock-N-Stitch Full-Torque Thread Inserts
This salvage procedure consists of drilling out the damage threads and tapping new threads, then installin
the new Full-Torque insert. What makes this insert different from other thread inserts is the spiral hook
threads that only transfer a radial drawing force to the surrounding material. This allows you to repair
cracked bolt holes, because the insert will contain the force of the bolt. It also can be used along with the
locks and pins to repair cracked castings.
Illustration 6
Full-Torque Thread Repair Insert
Note: For further information on Full-Torque thread inserts refer to SEBF8882 Using Lock-N-Stitch
Procedures for Casting Repair.
Some application may have to thin of wall to allow the use of a Full-Torque insert.
¾ Any hole with the damaged or cracked threads
¾ Ductile iron wheels
13. Threaded Inserts
This salvage procedure consists of enlarging damaged threaded holes, tapping the hole with an oversize t
and installing a threaded insert.
Some applications may not have enough material in the hole boss to install an insert.
Replacement of damaged threads.
Machine Shop Practices
Note: The contents of this section are summaries of more detailed information. They are intended to
supplement, not replace, the knowledge and skills possessed by experienced machinists.
Several aspects can affect the quality of machining operations used for parts salvage, and sometimes mak
the difference between success and failure. The most easily controlled aspects are cutter and workpiece
speed and feed rates, depth of cut, type, geometry and condition of cutting tool. Machine tool rigidity,
available horsepower, and the correct choice and maintenance of the cutting fluid are less obvious and no
as easy for the machinist to control.
"Quality" of the machining operations can be described both in terms of visually observed "Surface Finis
and "Subsurface Material alterations".
Surface Finish
Surface finish or more correctly, "surface texture", refers to the roughness, waviness, lay and flaws for a
given surface. No universal values for finished surfaces for these characteristics are given in this Guidelin
because of the different application requirements. The following definitions will help you understand the
relationship of "surface finish" and the aspects contributing to the finish. (Refer to Illustrations 7 and 8.)
Surface: The boundary that separates an object from another object, substance or space.
Surface Texture: The repetitive or random deviations from the nominal surface, which form the three-
dimensional topography of the surface. Surface texture includes roughness, waviness, lay and flaws. See
Illustration 7.
Roughness: Consists of the finer irregularities of the surface texture, usually producing those
irregularities, which result from the inherent action of the production process. These are considered to
include traverse feed marks and other irregularities within the limits of the sampling length.
Roughness Average (Ra): The arithmetic average of the absolute values of the measured profile height
deviations taken within the roughness sampling length and measured from the graphical centerline. For
electrical averaging instruments, the term "cutoff" is used to represent the roughness sampling length.
Roughness Average is also known as Arithmetical Average (AA) and Centerline Average (CLA). Older
instruments calibrated to display "RMS" values will give values 11% higher than Roughness Average
(Ra).
NOTE: Both American National Standard ANSI B46.1-1978 and International Standard ISO R468
describe and standardize acceptable measuring instrumentation for surface texture, and should be availab
to and read by everyone concerned with measuring surface texture. Copies are available in the United
States from the American Society of Mechanical Engineers, United Engineering Center, 345 East 47th
Street, New York, N.Y. 10017.
Waviness: The more widely spaced component of surface texture. Waviness includes all irregularities
whose spacing is greater than the roughness sampling length (cutoff) and less than the waviness sampling
length. Waviness may result from such aspects as machine or part deflections, vibration, chatter, heat
treatment, or warping strains. Roughness is considered to be superimposed on a "wavy" surface.
Lay: The direction or description of the predominant surface pattern, ordinarily determined by the
production method. See Illustration 9.
Flaws: Unintentional irregularities which occur at one place or at infrequent intervals on the surface. Flaw
include such defects as cracks, blowholes, inclusions, checks, tool drag, gouges and ridges. The effect of
flaws in included in Roughness Average (Ra) measurements.
Illustration 7
Detail of surface characteristics
Illustration 8
Interpretation of surface texture symbols
Illustration 9
Lay symbols and interpretation.
Subsurface Material Alterations
Note: The information in this section is based on data contained in the "Machining Data Handbook, 3rd
Edition", published by Machinability Data Center, Metcut Research Associates Inc., 3980 Rosslyn Drive
Cincinnati, Ohio, 45209.
All machining operations performed on a part will cause subsurface alterations of the material. The
alterations, usually occurring within the first 0.38 mm (0.015 inch), include such defects as cracks,
hardness changes, laps, folds and seams, metallurgical transformations, pits, residual stresses, etc.
While the alterations may not cause problems during rough machining operations, in low stress
applications, or with parts having wide surface feature tolerances, they could have serious consequences i
they occur on highly loaded, closely toleranced parts.
Good machining practices will minimize subsurface material alterations. Refer to the following sections,
"Chip Cutting Guidelines" and "Abrasive Processes", for guidelines to reduce the possibility or material
alterations.
Chip Cutting Guidelines
a. Keep cutting edges sharp. Dull tools promote plastic flow of the work surface with resulting tears, la
and roughness. Those surface defects can produce places for stresses to concentrate and may result in
fatigue failures. For finish cuts, the wear land on the cutter flank should not exceed 0.13 to 0.20 mm
(0.005 to 0.008 inch), which is the point the wear becomes visible.
The extra heat generated by dull cutting edges will also cause changes in metallurgy and surface burns.
The metallurgy changes can result in either excessively hard or soft surfaces. Remove surface burns,
which can be as deep as 0.25 mm (0.010 inch), to prevent the possibility of fatigue cracking.
b. Keep drill cutting edges sharp (maximum wear land of 0.13 to 0.20 mm (0.005 to 0.008 inch) to
minimize tears, laps and changes in metallurgy, especially in highly loaded parts.
Avoid hand-fed drilling operations to prevent hole damage caused by feed dwell. Also, use fixtures and/o
bushings to prevent damage. Provide chip clearance between the workpiece and drill bushing for holes
deeper than three times the diameter.
c. Ream holes 7.9 mm (0.31 inch) in diameter and larger in two steps. Allow a minimum diametrical
stock removal of 1.2 mm (0.05 inch). Allow at least 0.4 mm (0.02 inch) stock removal in smaller holes.
Deburr and chamfer any drilled and reamed holes to avoid potential fatigue failures. Remove at least 0.2
mm (0.01 inch) during the chamfering.
d. Inspect reamers after using. At the first sign of wear or chipping, replace them.
e. Honing with a multi-stone head produces the least change of workpiece surface of any conventional
operation of metal finishing.
f. Boring with sharp (new) cutting tools can, usually produce acceptable size accuracy and surface
texture. Tool wear land must not exceed 0.13 mm (0.005 inch).
Abrasive Processes
Machining (grinding) processes that are very abrasive may produce the greatest loss in fatigue strength of
the common processes.
a. Low stress grinding techniques reduce distortion and surface damage, and are recommended for final
grinding of heat treated or high strength steels. Results are accomplished by using softer grade grinding
wheels, dressing coarse wheels frequently, using lower feeds and speeds, and using lubricating type cuttin
fluids. Low stress grinding should be used for the final 0.25 mm (0.010 inch) of stock removal.
b. "Conventional" grinding is not recommended to finish grind heat-treated or high strength steels. The
heat-affected zone can be much deeper than surface color indicates. High stresses created in conventional
grinding can cause the workpiece to crack days after the grinding is completed, or prematurely in service
c. The hand grinding process creates a lack of control, which can produce unpredictable surface integrit
and should be avoided if possible.
d. Honing generates a true cylindrical form with respect to roundness and straightness. It also generates
final dimensional accuracy with low tolerances and provides high quality surface finishes with the least
amount of taper.
Cutter and Workpiece Feeds And Speeds; Depth Of Cut
Feeds, speeds and depths of cut depend upon many variables, as well as what is required for the workpiec
At best, any suggested combination of feeds, speeds and depth of cut is a starting point. Several aspects
would require adjustments to those settings. They are: compensating for variations in machine tool
horsepower, rigidity and condition; cutting edge type and condition; and operator skill and attitude. Also,
workpiece material, the amount of material removed and the numbers of cuts to remove the material, and
the desired surface texture and surface integrity will affect the settings used.
Because of the many variables involved in selecting a feed/speed/depth of cut combination, and the
machinist guides that are currently available, no specific recommendations are included in this guideline.
Note: Excellent sources of machinability information are:
The Machining Data Handbook",

3rd Edition, published by Machinability Data Center, Metcut Research Associates Inc., 3980 Rosslyn
Drive, Cincinnati, Ohio, 45209.
Machinery's Handbook", 23rd Edition, published by Industrial Press Inc.,

200 Madison Avenue, New York, N.Y., 10157.
Crack Detection
Crack Detection Systems
Crack detection systems commonly used are dye and fluorescent liquid penetrants, dry powder and liquid
magnetic particle methods, and ultrasonic testing. There may be more than one acceptable crack detection
system for the inspection of a given part, although the fluorescent penetrant is the most versatile. Select th
method that best fits your shop's operation. Sometimes, characteristics of a particular part may prevent th
use of certain inspection systems. For example, a liquid penetrant system cannot be used to inspect for
subsurface cracks in a steel part. Use Table 5 to determine the best system for the type of structure being
inspected.
Table 5
Table 5
Inspection System vs. Material Structure

Type Of Structure
Inspection Weld
Method Joint Nonferrous Ferrous
Dye Penetrant X X X
Fluorescent
X X X
Penetrant
Dry Magnetic 1 - X
Particle
Liquid Magnetic 1 - X
Particle
Ultrasonic
X X X
Testing
1 Magnetic particle inspection of any steel or cast iron weld joint will always show a crack indication.
Advantages and Disadvantages
Table 6
Table 6
Advantages vs. Disadvantages
Detection System Advantages Disadvantages
Dye Penetrant Least expensive. Least sensitive.
Minimal training required. Detects only surface cracks.
Completely portable.
Works on nonmagnetic parts.
Fluorescent Penetrant More expensive. Requires power for light.
More sensitive. Detects only surface cracks.
Works on nonmagnetic parts.
Dry Magnetic Particle Completely portable. Works only on magnetic parts.
Fast. Not as sensitive as fluorescent materials.
Liquid Magnetic More sensitive than dry powder. Requires power for light.
Particle Detects subsurface as much as Works only on magnetic parts.
0.13 mm (0.005 inch). Liquid composition and agitation must b
monitored.
Ultrasonic Testing Most sensitive. Most expensive.
Detects very deep material Requires operator training and
defects. certification.
Tooling Available
Liquid Penetrants
Dye: 4C-4736 Dye (Includes cleaner, dye and developer)

Fluorescent: 4C-4714 Black Light, 4C-4715
Clamping Fixture for Black Light, 4C-4737
Cleaner/Remover Fluid, 4C-4738 Penetrant,
4C-4739 Developer
Magnetic Particle
Dry powder: 4C-4735 Kit (Includes magnetic yoke, powder, cleaner)
Note: Liquid Magnetic Particle: Not offered by Caterpillar Inc. Use commercially available material.
Note: Caterpillar Inc does not offer ultrasonic Testing Equipment. A specially trained operator is requir
to use and interpret the ultrasound equipment and data.
Inspection Procedures
To inspect for cracks using the liquid penetrants and magnetic particle systems, use the procedures outlin
in the following series of illustrations prepared by the Magnaflux Corporation.
Follow these general precautions whenever using

these methods of crack detection to prevent
personal injury. Never shine the black light
directly into the eyes. Do not smoke or eat while
using inspection chemicals. Wash hands
thoroughly after using the chemicals. Avoid
getting the chemicals on clothing. Avoid inhaling
spray mist, airborne powder dust and solvent
vapors. Provide adequate ventilation. Store
chemicals away from open flames or sources of
heat.
Illustration 10
© 2004 Caterpillar
Printed in the U.S.A
All Rights Reserved
Copyright 1993 - 2006 Caterpillar Inc. Fri Jun 30 12:22:43 CDT 2006
Todos los derechos reservados.
Red privada para licenciados del SIS.

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Búsqueda avanzada de texto completo - SEBF8148 - General Salvage and Reconditioning...

Producto: NO SE HA ESCOGIDO NINGUN EQUIPO

Pautas de reutilización y recuperación

General Salvage and Reconditioning Techniques

• Various repair and salvage methods.

Important Safety Information

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

Notice labels in this publication identify

current information available before you start any job.

Do not operate or work on this product until you

Hot oil and components can cause personal injury.

When you check for a leak, use a board or

Types Of Salvage Procedures

1. Machine and sleeve to standard size.

General Salvage Procedures

1. Machine and Sleeve to Standard Size

Simple cylindrical sleeve

Sleeve against a shoulder in the bore

Sleeve with a flange

Sleeve against a shoulder on OD of bore.

Simple Cylindrical ID Sleeve

b. Apply 6V-1541 Quick Cure Primer to the sleeve OD and bore.

c. Apply a thin film of 9S-3265 Retaining Compound to the sleeve OD.

Simple Cylindrical OD Sleeve

c. Apply a thin film of 9S-3265 Retaining compound to the shaft OD.

Other Sleeve Design Requirements

b. Bores with rotating shafts.

c. Repair of reaction dowel holes in transmission clutch housings.

Seal ring bores and piston ring bores.

b. Transmission clutch piston bores (for cast iron seal rings).

c. Transmission clutch piston bores (for Teflon seal rings).

d. Transmission and torque converter housings, cages, and manifolds.

i. Hydraulic pump parts.

3. Weld and Cut To Standard Size

b. Potential for heat-induced warpage must be considered.

c. Potential for annealing or cracking heat-treated shafts.

a. Seal wear areas.

b. Bearing support (shafts and bores).

c. Worn dowel holes.

d. Loader frames and ripper frames.

e. Track roller frames.

f. Hydraulic cylinder eyes.

b. Potential for heat-induced warpage must be considered.

a. Weldable areas damaged by external forces.

b. Track rollers, links and idlers.

d. Crankcase guards (belly pans).

5. Thermal Spray and Machine to Standard Size Procedure Description

a. No impact or point-loading applications currently recommended.

a. Seal wear areas.

b. Bearing support (shafts and bores).

c. Worn dowel holes.

e. Cylinder rods and struts (HVOF).

a. No impact or point-loading applications.

b. Quality of coating is very dependent upon process control.

c. Operational temperature limitations.

a. Engine cylinder blocks.

d. Crack repair (nonstructural).

8. Machine, Chrome Plate and Machine To Standard Size

a. No impact or point-loading applications.

b. Quality of coating is very dependent upon process control.

a. Seal wear areas.

b. Bearing support (shafts and bores).