sebf8185

8/21/2020 SIS 2.
Thermal Spray and Salvage Procedure of Final Drive Planet Gear Bores for
2019/11/27
Certain Off-Highway Trucks (OHT) {4050, 4055} (SEBF8185)
SMCS - 4050,4055 i07946134

Off-Highway Truck/Tractor
773D (S/N: 7ER1-UP)
784B (S/N: 5RK1-UP)

784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

785D (S/N: DMC1-UP; MSY1-UP)
785G (S/N: TRG1-UP; RTL1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP; TWP1-UP)

789G (S/N: TR21-UP)
793F (S/N: D3T1-UP)
Introduction
Revision Summary of Changes in SEBF8185
Changed title from "Salvage Procedure for Final Drive Planet Gear Used in
Off-Highway Trucks" to "Thermal Spray and Salvage Procedure of Final
Drive Planet Gear Bores for Certain Off-Highway Trucks (OHT)"
Inserted the contents from SEBF2180"Thermal Spray Procedures for Off-
06
Highway Truck Final Drive Planet Gear" in to this media.
Updated effectivity.
Added tables 2,3, 4, 5, 6 and 7.
Added the "Crack Detection Methods" section.
05 Changed group effectivity to individual and added Metal Spray Guidelines.
04 Updated group effectivity.
Updated introduction, added"Canceled Part Numbers and Replaced Part
03
Numbers" and part numbers.
Table 1
© 2019 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).
Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning
additional repair options or modifications to reuse and salvage techniques and/or
methods.


©2020 Caterpillar Inc. Privacy & Legal
https://sis2.cat.com/#/detail?keyword=sebf8185&tab=3&serialNumber=&infoType=43&serviceMediaNumber=SEBF8185&serviceIeSystemControlNumber=i03919505 1/16
8/21/2020 SIS 2.0
To report suspected errors, inaccuracies, or suggestions regarding the document, submit

a form for feedback in the Service Information System (SIS web) interface.
Canceled Part Numbers and Replaced Part

Numbers
This document may include canceled part numbers and replaced part numbers. Use the
Numerical Part Record (NPR) on the Service Information System website (SIS web) for
information about canceled part numbers and replaced part numbers. NPR will provide
the current part numbers for replaced parts.
Important Safety Information
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 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.
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”. Refer to Illustration 2 for an
example of a “WARNING” Safety Alert Symbol.
This safety alert symbol means:
Pay Attention!


8/21/2020 SIS 2.0
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, 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.
Summary
This guideline provides the procedures necessary to determine the reusability of the final
drive planetary gear. Life will vary depending on application, load, lubrication, and
environment.
This guideline contains the latest standards of engineering, which will help minimize
owning and operating costs. A part is expected to reach the next Planned Component
Rebuild (PCR) if the part meets the specifications within this guideline and the part is
intended for a similar application. Use this guideline to determine whether a part should
be reused. Do not install a part that is not reusable. During reconditioning, correct any
condition that might have caused the original failure.
The dimensions and tolerances provided are to return a part / component to specification.
The dimensional information alone is not solely used to condemn a part from reuse.
Follow visual inspections and the "Crack Detection Methods" section for further guidance.
First reduction planet gears in the final drives for Off-Highway Trucks sometimes
experience inside diameter (ID) damage. This damage is caused when the bearing cup of
the bearing assembly rotates inside the bore. An engineering change in all newly
released parts has been made to increase the press fit between the bearing cup and the
inside bore of the gear. This guideline provides the method and specifications to rework
gears to the new engineering specifications.
Final drive gears that meet the reuse/salvage specifications can be expected to perform
normally in the same application until the next overhaul. Never install a part that this
Guideline indicated cannot be used again. Before installing a used or reconditioned part,
correct any conditions that may have caused the original wear.
References
References
Media
Publication Type & Title
Number
"Gear Tooth Inspection"
https://channel1.mediaspace.kaltura.com/media/Gear+Tooth+Inspection/1_5ujdi5zp
Channel1
"Why Reuse and Salvage Parts"
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Special Publication
PERJ1017
"Dealer Service Tools Catalog" 

8/21/2020 SIS 2.0
Reuse and Salvage Guidelines

SEBF8193
"Reusability of Drive Train Gears"
Reuse and Salvage Guidelines
SEBF9240
"Fundamentals of Flame Spray for Reconditioning Components"
Table 2
Service Advisories, Service Letters, and

Technical Service Bulletins
NOTICE
The most recent Service Advisories, Service Letters, and
Technical Service Bulletins that are related to this component
should be reviewed before beginning work. Often Service
Advisories, Service Letters, and Technical Service Bulletins
contain upgrades in repair procedures, parts, and safety
information which pertain to the components being repaired.
Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required
to perform every task within this document. Tooling needs may vary for the scope of work
to be performed for each specific rebuild.
Required Tooling and Equipment
Part
Description Designation
Number
— (1) Personal Protective Equipment (PPE) Personal Protection
Surface
— (2)
Holder (Disc Pad) Preparation
1U-5519
/ De-burring
Insert Tool Holder and C-2 grade Carbide Surface
—
Inserts Preparation
Machining
— Lathe with a 12 inch swing
Equipment
6V-2010 Polishing Stone Gear Polishing
1U-9918 Brush General Cleaning
1U-5512 Abrasive Material (Roll) General Cleaning
8T-7765 Surface Reconditioning Pad (180 Grit) General Cleaning
162-5791 Towel General Cleaning
Tool Group
8T-5096 Run-Out Checks
Dial Indicator
Instrument Group
Micrometer, Inside
473-8688 2.00 - 12.00 inch Internal
or Measurement
473-8689 Instrument Group Checks
Micrometer, Inside
50 - 300 mm
Automatic Tape Measure (1-inch X 26- ft)
1U-9367 Visual Testing (VT)
25.4- mm x 8- m
8S-2257 Magnifying Glass Visual Testing (VT)
9U-6182 Mirror (Telescoping) Visual Testing (VT)
9U-7231 Flashing Lights Conversion Kit Visual Testing (VT)
4C-9442 Light Visual Testing (VT)
— (2) Bright Incandescent Light Visual Testing (VT)
— Reflective Surface for Inspection Visual Testing (VT)
Liquid Penetrant
288-4209 Paper Towel
Testing (PT) 
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8/21/2020 SIS 2.0
General Cleaning/
Brush
1U-9915 Liquid Penetrant
Curved Handle Wire
Testing (PT)
Liquid Penetrant
— Developer
Testing (PT)
Liquid Penetrant
— Penetrating Oil
Testing (PT)
General Cleaning/
— Solvent Cleaner Liquid Penetrant
Testing (PT)
Dry Magnetic
263-7184 Crack Detection Kit (Magnetic Particle) Particle Testing
(MT)
Dry Magnetic
— Paint Pen Particle Testing
(MT)
Wet Magnetic
Lamp Group
459-0184 Particle Testing
Ultraviolet
(MT)
Table 3
(1)
Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment
(2) (PPE) part numbers suitable by geographic location and local safety standards.
Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
Preparing Gears For Salvage

Planet Gear Bore Inspections
Typical example of a scored planet gear bore
The inside bore of the gear is scored from the removal of the bearing cup. This damaged
area is located between the arrows. The other damage that can be seen is caused by the
bearing cup spinning inside the bore.
After reworking on the gear according to the salvage procedure, then OK TO USE PART
AGAIN.
Illustration 4 g03427695 

Typical example of a planet gear that requires further inspection©2020
of the bore.
Caterpillar Inc. Privacy & Legal
8/21/2020 SIS 2.0
Complete Steps 1 through 4 to inspect the planet gear bore:
Typical example of cleaning a planet gear bore. After cleaning a planet gear bore, OK TO USE THIS PART
AGAIN.
(G) Planet gear bore before cleaning.
(H) Planet gear bore after cleaning.
1. Clean the planet gear bore thoroughly before inspecting.

Note: Planet gear bores can be cleaned with cleaner for parts and a nonmetallic
pad for rubbing that will not remove metal.
2. Visually inspect the planet gear bore for damage and wear.
Note: An adequate light source is necessary to inspect planet gear bore. An optical
magnifier may also be used.
3. Inspect the planet gear bore with a seal pick to detect any wear steps.
4. Perform Wet Magnetic Particle Testing (MT). Refer to the "Wet Magnetic Particle
Testing (MT)" section for testing instructions.
Measuring the Planet Gear Bore
NOTICE
Do not touch the cleaned and grit blasted planet gear bore.
Contaminants deposited from handling can affect the bond
strength of metal spray coating and contribute to future failure
of the gear.
Use an inside micrometer to measure the planet gear bore.
1. If the measurement of the planet gear bore is within tolerances listed in Table 4,
then OK TO USE PART AGAIN.
2. If the measurement of the planet gear bore measures larger than specified and
meets the reuse criteria, continue with the salvage procedure. If the planet gear
does not meet all the specifications within the guidelines, then DO NOT USE PART
AGAIN.
Salvage Procedure
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8/21/2020 SIS 2.0
Planet gear positioned in the lathe after centering.
1. After the planet gear bore is cleaned and grit blasted, for metal spray applications,
apply metal spray to the bore of the planet gear. Depending on the size of the bore,
apply approximately 0.25 mm (0.010) of metal spray material per side.
2. After metal spraying, chuck the gear into the lathe. Use a dial indicator to adjust TIR
(total indicator runout) and to center the OD (outside diameter) of the planet gear to
within 0.13 mm (0.005 inch) or less.
Finish Procedure
Bore of the gear has been finish machined.
1. Use a boring bar with a C-2 carbide insert to machine the bore as shown in
Illustration 7.
2. Follow the metal spray guidelines for the post-coating treatment prior to installing
the bearing cup into the plane gear bore.
Specifications
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8/21/2020 SIS 2.0
Typical example of a 789 Final Drive Planet Gear
Planetary Gear Bore Acceptable Dimension and Tolerance
Part
Dimension (A) Dimension (B)
Number
8W-3072 1.5 ± 0.5 mm Ø 136.436 ± 0.013 mm
117-1005(1) (0.06 ± 0.02 inch) 45° (5.3715 ± 0.0005 inch)
Table 4
(1)
The most current part number is identified inbold font when multiple part numbers are in a cell
Part Description
Base Metal 8822H Steel
Hardness
Table 5
Flame Spray Equipment and Procedure

Flame Spray Equipment
Maximum Surface Texture 3.6 µm (140.00 µinch)
Reason for Spraying Wear/scoring
Mating Part Contact Area & Material Bearing cup
Metco Equipment Type Metco 6P-II
Metco Material Metco 453
Finish Thickness As Required
0.51 to 0.64 mm (0.020 to 0.025 inch) per
Finishing Allowance
side
Spray Angle 90°
Substrate Pre-Heat Temperature

66° C (150° F) Do not direct flame on area 
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to be sprayed
8/21/2020 SIS 2.0
Substrate Temperature During Spraying

148° C (300° F)
Not to Exceed
Auxiliary Cooling If Desired
Rotation/Traverse Device Lathe
Rotation/Traverse Speed 91.4 SMPM (300.00 SFPM)
Surface Preparation Method Scotch Brite Pad and Grit blast
Finishing Method Machine
Machining Equipment Type Lathe
Recommended Cutter Grade C-2, 883 Carboloy, or equivalent
Table 6
Flame Spray Procedure
Flame Spray Process Check

Procedure
(6P) List
Clean Part Degrease in hot caustic solution
Undercut To "tru-up" surface
Chamfer 1.50 ± 0.50 mm (0.059 ± 0.020 inch) x 45°
Remove Oxide Use fiber flap brush or Clean/strip disc
Mask for Blast Duct Tape
Blast Equipment Pressure type only
Grit Type and Size 25/40 steel angular grit
Blast Air Pressure 620 kPa (90.0 psi)
Blast Nozzle to Work
50 mm (2.0 inch)
Distance
Mask for Spray Antibond or Blue Layout Dye
Spray Equipment Type 6P-II Hand Held Thermo Spray System
Auxiliary Cooling If desired
Nozzle 6P-C7A-K "K" Nozzle
6P-3/Cooling Air 140 - 170 kPa
Air Capacity/Pressure
(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)
5.5 kg (12 lb) per hour or 90 gr (3.2 oz) per
Spray Rate/Build Up
min
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed Of Part 213 RPM
Rotation Speed Of Part 91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun 15.24 SMPM (50.000 SFPM)
Gun Fixturing Method Machine mount or hand held
0.10 to 0.15 mm (0.004 to 0.006 inch) per
Top Coat/Thickness
pass
Finishing Equipment Lathe
Part/Cutter Rotation 91.4 SMPM (300.00 SFPM)
0.05 to 0.10 mm (0.002 to 0.004 inch) per
Traverse Speed
revolution
0.38 to 0.51 mm (0.015 to 0.020 inch) per
Depth of Rough Cut
side
0.25 to 0.38 mm (0.010 to 0.015 inch) per
Depth of Finish Cut
side
Additional Finish Method Emery cloth for desired finish 
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8/21/2020 SIS 2.0
Table 7
Crack Detection Methods
NOTICE
Regardless of which crack detection method is used, it is
important that the instructions furnished with the detection
equipment are followed closely when checking any component.
Failure to do so may cause inaccurate results or may cause
injury to the operator and/or surroundings.
There are four major crack detection methods or Non-Destructive Testing (NDT) listed in
this section: Visual Testing (VT), Liquid Penetrant Testing (PT), and Dry / Wet Magnetic
Particle Testing (MT).
Crack detection methods or NDT is methods for testing components for cracks without
damaging the component. VT, PT, Dry/ Wet MT, and UT are methods recommended.
There may be more than one acceptable crack detection method for the testing of a given
part, although PT is the most versatile. For example, the PT method can be used when
testing smooth machined components such as shafts, gear teeth, and splines, but using
the Wet MT is more accurate. Refer to Table 8 for advantages and disadvantages and
Table 9 for standards and requirements for these NDT methods.
Crack Detection Methods Advantages and Disadvantages
Detection
Advantages Disadvantages
Method
- Least Expensive
- Detects most - Limited to surface-only defects.
Visual
damaging defects. - Requires inspectors to have broad knowledge
Testing
- Immediate Results of welding and fabrication in addition to Non-
(VT)
- Minimum part Destructive Testing (NDT).
preparation
- Inexpensive
Liquid - Minimal Training
- Least Sensitive
Penetrant - Portable
- Detects surface cracks only.
Testing - Works on
- Rough or porous surfaces interfere with test
(PT) nonmagnetic
material.
- Portable
Dry - Fast/Immediate
- Works on magnetic material only.
Magnetic Results
- Less sensitive than Wet Magnetic Particle
Particle - Detects surface and
Testing (MT).
(MT) subsurface
discontinuities
- More sensitive than
Wet Liquid Penetrant - Requires power for light.
Magnetic Testing (PT). - Works on magnetic material only.
Particle - Detects subsurface - Liquid composition and agitation must be
(MT) as much as 0.13 mm monitored.
(0.005 inch).
Table 8
Applicable Crack Detection Standards
Minimum
Acceptance Required
Detection Method Standard
Criteria Personnel
Qualifications
EN-ISO 5817 - Level
EN-ISO EN-ISO 9712
B
Visual Testing (VT) 5817 ANSI-ASNT SNT-TC-
AWS D1.1 - Table
AWS D1.1 1A
6.1
EN-ISO EN-ISO 9712
Liquid Penetrant Testing EN-ISO 23277
3452 ANSI-ASNT SNT-TC-
(PT)
ASTM E165
AWS - D1.1
1A 
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8/21/2020 SIS 2.0
EN-ISO 23278 -
EN-ISO EN-ISO 9712
Magnetic Particle Testing Level 1
17638 ANSI-ASNT SNT-TC-
(MT) AWS D1.1 - Table
ASTM E709 1A
6.1
Table 9
Visual Testing (VT)
Example of Visual Testing (VT) Tooling
(A) Flashlight (or adequate light source)
(B) Magnifying Glass
(C) Tape Measure (or other measuring device)
(D) Inspection Mirror
Refer to Tooling and Equipment Table 3 for part numbers.
Components and welds that are to be tested using PT, MT, or UT shall first be subject to
a Visual Testing (VT). VT is often the most cost-effective inspection method and requires
little equipment as seen in Illustration 9. Personnel performing VT shall either be trained
to a company standard or have sufficient experience and knowledge regarding the
components being inspected. Personnel performing VT shall take routine eye exams.
Liquid Penetrant Testing (PT)
Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment

required to do the job.
Make sure that you read and understand all directions and
hazards described on the labels and material safety data sheet
of any chemical that is used.
Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of chemicals.
Materials and Equipment Required

Refer to Tooling and Equipment Table 3for part numbers.
Cleaner: Removes dirt before dye application and dissolves the penetrant making
possible to wipe the surface clean.
Penetration Oil: This solution is highly visible, and will seep into openings at the
surface of a part with capillary action.
Developer: Provides a blotting action, bringing the penetrant out of the

discontinuities and providing a contrasting background to increase the visibility of
the penetrating oil indications.
Wire Brush: Removes dirt and paint.
Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure 
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8/21/2020 SIS 2.0
Typical example of pre-cleaning the testing area.
1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt,
or any oil. Wipe the area to be tested with a solvent dampened cloth to remove
remaining dirt and allow the area to dry. Remove paint where there are visible
cracks using paint remover or a wire brush.
Typical example of applying penetrating oil to areas to be tested.
2. Apply penetrating oil by spraying to the entire area to be tested. Allow 10 to 15

minutes for penetrating oil to soak. After the penetrating oil has been allowed to
soak, remove the excess penetrating oil with clean, dry wipe.
Typical example of removing penetrating oil with a cloth.
3. The last traces of penetrating oil should be removed with the cleaner solvent
dampened cloth or wipe. Allow the area to dry thoroughly. 
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8/21/2020 SIS 2.0
Typical example of applying the developer.
4. Before using developer, ensure that the developer is mixed thoroughly by shaking
the container. Hold the container approximately 203 - 305 mm (8 - 12 inch) away
from part. Apply an even, thin layer of developer over the area being tested. A few
thin layers are a better application method than one thick layer.
Typical example of cracks found during Liquid Penetrant Testing (PT).
5. Allow the developer to dry completely for 10 to 15 minutes before inspecting for
cracks. Defects will show as red lines in white developer background, refer to
Illustration 14. Clean the area of application of the developer with solvent cleaner.
Dry Magnetic Particle Testing (MT)

Materials and Equipment Required
(A) Indications shown by Dry Magnetic Particle Testing (MT).
(B) Electromagnetic Yoke
(C) Dry Powder Bulb 
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8/21/2020 SIS 2.0
1. Dry magnetic powder shall be of high permeability and low retentively and of
suitable sizes and shapes to produce magnetic particle indications. The powder
shall be of a color that will provide adequate contrast with the background of the
surface being inspected.
2. Dry magnetic particles shall be stored in suitable containers to resist contamination

such as moisture, grease, oil, non-magnetic particles such as sand, and excessive
heat. Contaminants will manifest in the form of particle color change and particle
agglomeration. The degree of contamination will determine further use of the
powder.
3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18
(Evaluation of System Performance/Sensitivity) when not performing.
4. Equipment should include a "U" shaped electromagnetic yoke made from highly
permeable magnetic material, which has a coil wound around the yoke. This coil
carries a magnetizing current to impose a localized longitudinal magnetic field into
the part. The magnetizing force of the yoke is related to the electromagnetic
strength and can be tested by determining the lifting power of a steel plate. The
yoke shall have a lifting force of at least 4.5 kg (10 lbs).
5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-
like coating of the dry magnetic particles. Blower should also have sufficient force to
remove excess particles without disturbing those particles that are evidence of
indications.
6. All equipment shall be inspected at a minimum of once a year or when accuracy is

questionable.
Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil
scale, paint, and other contaminants.
2. Apply the magnetic field using the yoke against the faces and inside diameter of
each bore.
3. Simultaneously apply the dry powder using the dry powder blower.
4. Remove excess powder by lightly blowing away the dry particles.
5. Continue around the entire circumference of each bore. Position the yoke twice in
each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field
are created.
6. Observe particles and note if any clusters of particles appear revealing an

indication.
7. Record the size and shape of any discontinuities or indications found.
Wet Magnetic Particle Testing (MT)

Materials and Equipment
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8/21/2020 SIS 2.0
(A) Indications shown by Wet Magnetic Particle Testing (MT).
(B) Electromagnetic Yoke
(D) Ultraviolet Lamp
Pear Shaped Centrifuge Tube
1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given
concentration that will allow application to the test surface by spraying.
2. Concentration:
a. The concentration of the suspended magnetic particles shall be as specified

by the manufacturer and be checked by settling volume measurements.
b. Concentrations are determined by measuring the settling volume by using an

ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL
(0.0017 oz) divisions, refer to Illustration 17. Before sampling, the suspension
shall be thoroughly mixed to assure suspension of all particles, which could
have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and
allowed to settle for 30 minutes. The settling volume should be between
0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.
c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned

water.
d. The oil shall have the following characteristics:
Low viscosity not to exceed 5 mm2/s (5 cSt) at any temperature at which

the vehicle is to be used.
Low inherent fluorescence and be non-reactive.
e. The conditioning agents used in the conditioned water shall have the following
characteristics:
Impart good wetting characteristics and good dispersion.



Minimize foaming and be non-corrosive.
8/21/2020 SIS 2.0
Low viscosity shall not exceed a maximum viscosity of 5 mm2/s (5 cSt)

at 38° C (100° F).
Non-fluorescent, non-reactive, and odorless.
Alkalinity shall not exceed a pH of 10.5.
3. Equipment should include a "U" shaped electromagnetic yoke made from highly
permeable magnetic material, which has a coil wound around the yoke. This coil
carries a magnetizing current to impose a localized longitudinal magnetic field into
the part. The magnetizing force of the yoke is related to the electromagnetic
strength and can be tested by determining the lifting power of a steel plate. The
yoke shall have a lifting force of at least 4.5 kg (10 lbs).
Procedure
1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil
scale, paint, and any other contaminants.
2. Apply the magnetic field using the yoke against the surface in the area to be
inspected.
3. For case hardened and ground surfaces:
Due to the sensitivity required to locate the grinding cracks, inspection of case
hardened and ground surfaces require that the yoke is applied so that the
magnetic field is 1.57 rad (90°) to the expected direction of the indications.
Also, due to the increased sensitivity resulting when the yoke is energized, the
yoke is not moved until the evaluation is completed in the first direction. An
AC yoke shall be used. See Illustration 18 for an example of yoke placement.
4. Visually inspect for indications of discontinuities using the proper illumination.
5. Record the size and shape of any discontinuities found.



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8/21/2020 SIS 2.

SMCS - 4050,4055 i07946134

784B (S/N: 5RK1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

785G (S/N: TRG1-UP; RTL1-UP)

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

789D (S/N: SPD1-UP; SHH1-UP; TWP1-UP)

793F (S/N: D3T1-UP)

Information contained in this document is considered Caterpillar: Confidential

To report suspected errors, inaccuracies, or suggestions regarding the document, submit

Canceled Part Numbers and Replaced Part

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Your safety is Involved.

Caterpillar cannot anticipate every possible circumstance that might involve a

Reuse and Salvage Guidelines

Service Advisories, Service Letters, and

Tooling and Equipment

Required Tooling and Equipment

Preparing Gears For Salvage

Complete Steps 1 through 4 to inspect the planet gear bore:

1. Clean the planet gear bore thoroughly before inspecting.

Measuring the Planet Gear Bore

Use an inside micrometer to measure the planet gear bore.

Flame Spray Equipment and Procedure

Substrate Pre-Heat Temperature

Substrate Temperature During Spraying

Flame Spray Procedure

Flame Spray Process Check

Crack Detection Methods

Crack Detection Methods Advantages and Disadvantages

Applicable Crack Detection Standards

Visual Testing (VT)

Liquid Penetrant Testing (PT)

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment

Observe all safety precautions recommended by the chemical

Materials and Equipment Required

Developer: Provides a blotting action, bringing the penetrant out of the

Wire Brush: Removes dirt and paint.

2. Apply penetrating oil by spraying to the entire area to be tested. Allow 10 to 15

Dry Magnetic Particle Testing (MT)

2. Dry magnetic particles shall be stored in suitable containers to resist contamination

6. All equipment shall be inspected at a minimum of once a year or when accuracy is

4. Remove excess powder by lightly blowing away the dry particles.

6. Observe particles and note if any clusters of particles appear revealing an

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MT)

a. The concentration of the suspended magnetic particles shall be as specified

b. Concentrations are determined by measuring the settling volume by using an

c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned

d. The oil shall have the following characteristics:

Low viscosity not to exceed 5 mm2/s (5 cSt) at any temperature at which

Low inherent fluorescence and be non-reactive.

Impart good wetting characteristics and good dispersion.

Low viscosity shall not exceed a maximum viscosity of 5 mm2/s (5 cSt)

Non-fluorescent, non-reactive, and odorless.

Alkalinity shall not exceed a pH of 10.5.