Инструкция по повторному использованию шпинделей передних ступиц 785, 789

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Product: TRUCK
Model: 789D TRUCK SPD
Configuration: 789D Off-Highway Truck SPD00001-UP (MACHINE) POWERED BY 3516 Engine
Reuse And Salvage Guidelines

Inspection and Salvage of Front Wheel Spindles for Off-Highway Trucks{4201, 4205}
Media Number -SEBF9309-04 Publication Date -22/07/2015 Date Updated -22/07/2015
Caterpillar: Confidential Yellow
i06239309
Inspection and Salvage of Front Wheel Spindles for Off-Highway

Trucks{4201, 4205}
SMCS - 4201; 4205
Off-Highway Truck/Tractor: All
Introduction
Table 1
Revision Summary of Changes in SEBF9309
04 Corrected dimension in Table 6.
03 Added one part number.
02 Added salvage process for 793.
© 2015 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
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 13.03.2016
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• Dealer Solution Network
• Caterpillar Technical Representative
• Knowledge Network
Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for
information about canceled part numbers and replaced part numbers. NPR will provide the current part
numbers for replaced parts.
Important Safety Information
Illustration 1 g02139237
Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused
by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. Personnel should be properly trained in order to perform maintenance,
repair, or operate any machine. Safety precautions and warnings are provided this instruction and on
Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar
cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the product are not all inclusive.
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 in Illustration
1.
This safety alert symbol means:
Pay Attention!
Become Alert!
Your Safety is Involved.
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.
Service Letters and Technical Information Bulletins
NOTICE
The most recent Service Letters and Technical Information Bulletins

that are related to this component shall be reviewed before beginning
work. Often Service Letters and Technical Information Bulletins
contain upgrades in repair procedures, parts, and safety information
that pertain to the parts or components being repaired.
Welder Qualifications
Protect yourself and others; read and understand this warning. Fumes
and gases can be dangerous to your health. Ultraviolet rays from the
weld arc can injure eyes and burn skin. Electric shock can kill.
Read and understand the manufacturer's instruction and your

employer's safety practices. Keep your head out of the fumes. Use
ventilation, exhaust at the arc, or both, to keep fumes and gases from
your breathing zone and the general area. Wear correct eye, ear and
body protection. Do not touch live electric parts.
Refer to the American National Standard Z49.1, "Safety in Welding

and Cutting" published by the American Welding Society, 2501 N.W.
7th Street, Miami, Florida 33125: OSHA Safety and Health Standards,
29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C.
20210.
Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing
237-5181
Respirator for breathing protection.
Welders must be qualified for the appropriate type of weld that is being performed. Shielded Metal Arc
Welding (SMAW) or Flux Cored Arc Welding (FCAW). Qualifications should be in accordance with
ANSI/AWS D1.1, D14.3, or Caterpillar Manufacturing Practice MC1000-105. Welders must be qualified for
the appropriate position of weld that is being performed. Refer to AWS Specifications D1.1 and D14.3 or
comparable standards for information that regards qualification requirements. The welders must have used
the process at some time within the last 6 months. The welders must complete the process of certification if
the welders have not used the welding processes for 6 months. The welding operator must hold a current
certification for this process.
Summary
This guideline provides the procedures that are necessary to determine the reusability for front spindles / front
axles on Off-Highway Trucks.
This guideline contains the latest standards of engineering, which will help minimize owning and operating
costs. A part can be expected to reach the next Planned Component Repair if the part meets the specifications
in this guideline and if the part is used in the same application. Use this guideline in order 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.
Standardized Parts Marking

Reference Refer to Reuse And Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures" for
additional information regarding marking procedures.
NOTICE
Do not use a number metal stamp set to mark parts. The impact from
striking the stamp will cause an abnormal stress riser. The added stress
riser may cause premature part failure.
Note: Use metal marking pen for all marking.
The procedure for marking includes a code that will identify the number of rebuilds and the number of hours
on each rebuild.
Illustration 3 shows code (1-15). The first number (1) indicates that the component had been rebuilt once. The second number (15)
indicates that there were 15,000 hours on the component at the time of rebuild.
Illustration 4 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first
number (2) indicates that the component had been rebuilt twice. The second number (10) indicates that there were 10,000 hours on
the component at the time of rebuild.
This coding can be used by all dealers and will help with identification at time of rebuild. Identification can
be especially helpful if units that have been rebuilt are sold into different territories. As new overhauls are
completed, the previous markings should be left on the part. To obtain the total amount of hours for the gear
in Illustration 4 you must add first and second rebuild hours. In this example the gear has a total of 22,000
hours.
References
Table 2
References
Media Number Title
SEBF8187 "Standardized Parts Marking Procedures"
SEBF8443 "Procedure to Inspect and Repair Wheels Used on Off-Highway Trucks"
SEBF9236 "Fundamentals of HVOF Spray for Reconditioning Components"
SEBF9238 "Fundamentals of Arc Spray for Reconditioning Components"
Checklist for Inspection and Salvage of Front Wheel Spindles /

Front Axles
Reuse Inspection
Table 3
Critical Features Type of Check
Entire spindle / front
Magnetic particle inspection and dye penetrant for cracks.
axle
Splines Measurement Over Pins
The hardness for each journal must be at a Rockwell rating of at least 30N 64.
(Rockwell C 45)
The tolerance of the OD for each journal is + 0.025 - 0.050 mm (+ 0.0010 -
Bearing journals
0.0020 inch).
The alignment of each journal must be measured to a tolerance of
± 0.025 mm (± 0.0010 inch).
Salvage
Table 4
Critical Features
Operation
Repair with Arc Spray or HVOF Refer to Table 5 for the hardness.
Bearing journals Machine the journals to size. Alignment must be measured to the value in Table 3.
Protective Equipment, Tools and Materials Needed

The following tools will be required to perform the repair procedures in this guideline.
Table 5
Part Number Description Qty
1U-5512 Polishing Cloth / Emery Cloth As needed
1U-5516 Discs (Coarse) As needed
1U-5518 Threaded Shaft 1
1U-5519 Disc Pad Holder 1
1U-9918 Wire Brush 1
4C-4804 Penetrating Oil As needed

4C-4805 Developer As needed
Welding Blanket
(
4C-9616 As needed
183 cm (72 inch) x
183 cm (72 inch))
5P-1720 Seal Pick 1
6V-6035 Hardness Tester 1
6V-6042 Indicator Point Gp 1
8S-2257 Eye Loupe 1
8T-5096 Dial Indicator Gp 1
8T-7765 Surface Reconditioning Pad As needed
9U-6382 Grinding Wheel As needed
9U-6383 Grinding Wheel As needed
162-5791 Shop Towels As needed
222-3074 Die Grinder 1
222-3076 Right Angle Die Grinder 1
222-3121 Rust Preventative Solution As needed
236-8097 Carbide Bur Bit 1
237-5181 Respirator 1
251-0030 Calibrated Infrared Thermometer 1
Flapper Wheel
254-5314 As needed
3" x 2" 120 grit
Flapper Wheel
254-5315 As needed
3" x 2" 240 grit
263-7184 Crack Detection Kit 1
Angle Grinder
288-2512 1
4½ inch
367-9109 Digital Caliper 1
Outside Micrometer Set
385-4008 1
6- 60 inch
420-5317 Suitable Cribbing As needed
459-0184 UV Lamp Kit 1
473-8690 1
0-4 inch
473-8691 1
2-6 inch
473-8692 1

6-12 inch
Precision Gage Pins
- 2
8.000 mm
(0.31496 inch)
- Arc Spray system or HVOF system 1
- Adequate lathe 1
Identification of Spindle / Front Axle Type

Illustrations 5, 6 show the typical configuration of front wheels on Off-Highway Trucks
Typical front spindle/ front axle.
Typical front spindle / front axle.
Identification of Areas that Wear
The area between the bearing and the spindle / front axle (arrows) can encounter wear.
Preparation Recommendations
Personal injury can result when using cleaner solvents.
To help prevent personal injury, follow the instructions and warnings

on the cleaner solvent container before using.
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Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
Typical burr removal tooling.
(A) Right Angle Die Grinder
(B) Die Grinder
(C) (D) (E) Conditioning Discs, Disc Pad Holder, and Threaded Shaft
(F) (G) Flapper Wheels
• Before you inspect the spindles / front axles, clean thoroughly to ensure that all components are free
from rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of an
unacceptable defect.
• Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent
damage to the part when you lift the part.
• During cleaning, do not damage machined surfaces.
• Use pressurized air to dry parts.
• Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done
immediately after cleaning. Carefully store the parts in a clean container.
• Inspect all flange mating surfaces and ensure that flange mating surfaces are true and free from raised
material resulting from rust, nicks, and dents.
• Use appropriate thread taps to chase all threaded holes.
General Guidelines
Inspect the spindle / front axle before the salvage procedure. The spindle / front axle should be inspected
immediately after disassembly and cleaning. To prevent a failure, inspect each of the following critical areas
of a spindle / front axle.
• Entire Spindle / Front Axle - Inspect the spindle / front axle for cracks. Use either a magnetic particle
or a liquid dye penetrant in the inspection process. An internal crack that is not detected or fully
removed before salvage can lead to failure.
• Splines - A cracked spline must not be salvaged. A spline that does not meet the dimensional
requirement cannot be salvaged. Because splines transfer high loads, thoroughly inspect each spline for
cracks. Measure the average dimension over pins in order to determine wear.
• Bearing Journals - Measure the surface hardness and the outside diameter for each journal. Bearing
journals may be salvaged by using Arc Spray or by using High Velocity Oxygen Fuel (HVOF).
• Mounting Flange Bolt Holes - These bolt holes may experience damage if bolts are loose during
operation. Inspect each bolt hole for deformation. You may salvage a deformed bolt hole by welding
the bore and machining the bore.
Always use proper lifting devices for the safety of the operator. Prevent damage to machined surfaces by
using the correct lifting equipment.
Visual Inspection
Wheel Bearing Journals
A wheel bearing journal can be visually inspected with the unaided eye. During an inspection, the best results
can be achieved with the use of a magnifying glass and a strong light source. Sunlight is the best light source.
If difficult to distinguish small scratches from cracks, use either a liquid dye penetrant or a magnetic particle
inspection.
Normal Wear
The following photos show both inner wheel bearing journal and outer wheel bearing journal. However, the
criteria for reusing either wheel bearing journal is identical.
The outer journal surface in this illustration has been laser hardened. The shiny area (A) has been buffed slightly in order to check
the hardness.
USE AGAIN
This is a laser hardened inner journal that exhibits normal wear. Once the corrosion has been removed from the surface, this part
may be reused.
USE AGAIN
This is an inner journal that exhibits normal wear.
USE AGAIN
This inner journal exhibits light wear and light pitting (B) .
USE AGAIN
Surface Damage
In order to recondition the surface of a bearing journal, refer to Reuse and Salvage, SEBF9236,
"Fundamentals of HVOF Spray for Reconditioning Components".
This bearing journal surface exhibits smearing damage (C). Before you reuse the spindle / front axle, buff the surface and verify
the dimensions.
Refer to Table 6.
USE AGAIN
This is a magnified view of Illustration 13. Before you reuse the spindle / front axle, buff the surface and verify the dimensions.
Refer to Table 6.
USE AGAIN
This is an outer journal that exhibits bruising (D). A band of corrosion (E) is shown below the journal.
DO NOT USE AGAIN
This journal may be salvaged using Reuse and Salvage, SEBF9236, "Fundamentals of HVOF Spray for Reconditioning
Components".
Note: If corroded (E) is the only damage, the spindle / front axle may be reused after you buff the corrosive
area.
This outer journal exhibits scratching and spalling damage.
DO NOT USE AGAIN
Components".
This is an outer journal that exhibits heavy damage from spalling.
DO NOT USE AGAIN
Components".
This outer journal has a layer of thermal spray material that is mostly gone.
DO NOT USE AGAIN
Components".
This is an inner journal that exhibits scratching and spalling damage.
DO NOT USE AGAIN
Components".
This inner journal has a layer of thermal spray material that has started to flake off. The bond between the journal and the thermal
spray material failed.
DO NOT USE AGAIN
Components".
The scalloped edge on the wheel has caused the inner bearing journal to wear a round groove into the spindle / front axle.
USE AGAIN
The depth of the groove must not exceed 2.00 mm (0.0787 inch). Buff the surface in order to eliminate sharp edges or grooves.
Hardness Testing
Typical example of performing a hardness test using 6V-6035 Hardness Tester.
Persons should be qualified or properly trained in how to use the hardness tester to insure good results.
Measure the hardness of bearing journals. The hardness must be at a Rockwell of at least 64 on the 30N scale.
This is equivalent to 45 Rockwell C.
Repair for Front Spindle / Front Axle Assembly

If diameter (A) and diameter (B) are worn, a Thermal Spray operation may be used to restore the diameter of
the bearing race to the original dimension. If you have questions concerning equipment, recommendations for
powder, machine settings, or procedures for the application, refer to the Reuse and Salvage, SEBF9238,
"Fundamentals of Arc Spray for Reconditioning Components" section of this guideline. Each step in the
procedure is critical to achieve the desired bond coating and the desired finish. Preparation of the spindle /
front axle is critical to achieve the desired bond and the desired finish of the coating. After the spindle / front
axle has been sprayed, mount the spindle / front axle assembly on a lathe. Zero the part on diameter (X) and
face (Y). Machine the spindle / front axle to the dimensions that are shown in Table 6. Diameter (A) and
diameter (B) must be within 0.038 mm (0.0015 inch). Both diameters must be within the maximum total
indicator reading of each other and face (Y).
Typical view of front spindle / front axle dimensions The surface finish (M) is 1.6 µm (63 µinch). Chamfer (P). Refer to Table 6
for the dimensions.
Table 6
Dimensions for Front Spindles / Front Axles
Spindle /
Chamfer Angle
Front Axle Diameter (A) Diameter (B) Length (L)
(P)
77.77 ± 0.013 mm 129.982 ± 0.013 mm

5D-8203 150.42 mm 30°
(3.062 ± 0.0005 inch) (5.1174 ± 0.0005
(5.922 inch)
inch)
6D-0093
120.620 ± 0.025 mm 139.670 ± 0.0254 mm
(4.7488 ± 0.0010 (5.4988 ± 0.0010

inch) (1) inch) 109.50 mm
(4.311 inch)
133.320 ± 0.025 mm 152.370 ± 0.025 mm

7D-2834 128.50 mm 30°
(5.2488 ± 0.0010 (5.9988 ± 0.0010
(5.059 inch)
inch) (1) inch)
124.0 + 20.0 - 0.0

231.745 ± 0.025 mm 317.470 ± 0.025 mm
8X-1468 mm 30°
(9.1238 ± 0.0010 (12.4988 ± 0.0010
(4.88 + 0.79 - 0.0
inch) (1) inch)
inch)
77.77 ± 0.013 mm 129.982 ± 0.013 mm

9M-1683 150.42 mm 30°
(3.062 ± 0.0005 inch) (5.1174 ± 0.0005
(5.922 inch)
inch)
6G-6440 133.320 ± 0.025 mm 152.370 ± 0.025 mm

128.5 ± 0.5 mm 30°
133-4727 (5.2488 ± 0.0010 (5.9988 ± 0.0010
(5.06 ± 0.02 inch)
inch) (1) inch)
161.0 + 20.0 - 0.0

346.032 ± 0.025 mm 415.874 ± 0.025 mm
144-0804 mm 30°
(13.6233 ± 0.0010 (16.3730 ± 0.0010
(6.34 + 0.79 - 0.0
inch) (1) inch)
inch)
124.0 + 20.0 - 0.0

260.3 ± 0.025 mm
174-7530 330.0 ± 2.0 mm mm 30°
(10.24801 ± 0.0010
(13.00 ± 0.10 inch) (4.88 + 0.79 - 0.0
inch)
inch)
5T-2098 130.0 + 20.0 - 0.0

152.370 ± 0.025 mm 199.944 ± 0.025 mm
9D-1388 mm 30°
(5.9988 ± 0.0010 (7.8718 ± 0.0010
183-7417 (5.12 + 0.79 - 0.0
inch) (1) inch)
inch)
5T-6063
111.0 + 20.0 - 0.0
8W-5599 231.745 ± 0.025 mm 269.845 ± 0.025 mm
mm 30°
8X-8950 (9.1238 ± 0.0010 inch) (10.6238 ± 0.0010
(4.37 + 0.79 - 0.0
183-7418 inch)
inch)
5T-6116 111.0 + 20.0 - 0.0

231.745 ± 0.025 mm 269.845 ± 0.025 mm
8X-9561 mm 30°
(9.1238 ± 0.0010 (10.6238 ± 0.0010
183-7419 (4.37 + 0.79 - 0.0
inch) (1) inch)
inch)
6G-6430
120.620 ± 0.025 mm 139.670 ± 0.025 mm 109.50 ± 0.5 mm
205-9071 30°
(4.7488 ± 0.0010 inch) (5.4988 ± 0.0010 (4.311 ± 0.02 inch)
205-9072
inch)
205-9073
133.320 ± 0.025 mm 152.370 ± 0.025 mm
(5.2488 ± 0.0010 inch) (5.9988 ± 0.0010

inch) 128.50 mm
(5.059 inch)
133.320 ± 0.025 mm 152.370 ± 0.025 mm

205-9074 128.50 mm 30°
(5.2488 ± 0.0010 inch) (5.9988 ± 0.0010
(5.059 inch)
inch)
260.3 ± 0.025 mm 317.45 ± 0.025 mm

244-7765 160.0 ± 0.5 mm 6°
(10.24801 ± 0.0010 (12.49801 ± 0.0010
(6.30 ± 0.02 inch)
inch) inch)
252-7959
120.620 ± 0.025 mm 139.670 ± 0.025 mm 109.50 ± 0.5 mm
252-7960 30°
(4.7488 ± 0.0010 inch) (5.4988 ± 0.0010 (4.311 ± 0.02 inch)
261-0650
inch)
167.97 + 20.0 - 0.0

346.032 ± 0.025 mm 457.15 ± 0.025 mm
278-8809 mm 30°
(13.6233± 0.0010 (17.9980 ± 0.0010
(6.613 + 0.79 - 0.0
inch) (1) inch)
inch)
167.97 + 20.0 - 0.0

346.032 ± 0.025 mm 457.15 ± 0.025 mm
375-0114 mm 30°
(13.6233± 0.0010 (17.9980 ± 0.0010
(6.613 + 0.79 - 0.0
inch) (1) inch)
inch)
124.0 + 20.0 - 0.0

231.745 ± 0.025 mm 317.470 ± 0.025 mm
386-5921 mm 30°
(9.1238 ± 0.0010 inch) (12.4988 ± 0.0010
(4.88 + 0.79 - 0.0
inch)
inch)
260.3 ± 0.025 mm
389-3912 330.0 ± 2.0 mm 160.0 ± 0.5 mm 6°
(10.24801 ± 0.00098
(13.00 ± 0.10 inch) (6.30 ± 0.02 inch)
inch)
(1)
The tolerance for reusability is + 0.025 /- 0.050 mm (+ 0.0010 /- 0.0020 inch).
Table 7
Mounting Flange Hole Dimensions for Front Spindles / Front Axles
Spindle / Front Axle Part Number Hole Diameter (+) Hole Tolerance (-) Hole Tolerance
5D-8203 22.631 mm 0.5 mm 0.150 mm

(0.891 inch) (0.020 inch) (0.006 inch)
6D-0093 24.0 mm 0.5 mm 0.150 mm

(0.945 inch) (0.020 inch) (0.006 inch)
7D-2834 19.750 mm 0.250 mm

(0.778 inch) (0.010 inch)
8X-1468
24.0 mm 0.5 mm 0.150 mm
(0.945 inch) (0.020 inch) (0.006 inch)
9M-1683 22.631 mm 0.5 mm 0.150 mm

(0.891 inch) (0.020 inch) (0.006 inch)
6G-6440
19.750 mm 0.250 mm 0.250 mm
133-4727
(0.778 inch) (0.010 inch) (0.010 inch)
144-0804 26.0 mm 0.5 mm 0.250 mm

(1.0236 inch) (0.020 inch) (0.010 inch)
174-7530 21.5 mm 0.5 mm 0.150 mm

(0.846 inch) (0.020 inch) (0.006 inch)
5T-2098
9D-1388 24.0 mm 0.5 mm 0.150 mm
183-7417 (0.945 inch) (0.020 inch) (0.006 inch)
5T-6063
8W-5599
24.0 mm 0.5 mm 0.150 mm
8X-8950
(0.945 inch) (0.020 inch) (0.006 inch)
183-7418
5T-6116
8X-9561 24.0 mm 0.5 mm 0.150 mm
183-7419 (0.945 inch) (0.020 inch) (0.006 inch)
6G-6430
24.0 mm
205-9071 0.5 mm 0.150 mm
(0.945 inch)
205-9072 (0.020 inch) (0.006 inch)
205-9073 19.750 mm 0.250 mm 0.250 mm

(0.778 inch) (0.010 inch) (0.010 inch)
205-9074 19.750 mm 0.250 mm 0.250 mm

(0.778 inch) (0.010 inch) (0.010 inch)
0.150 mm
244-7765 21.5 mm 0.5 mm
(0.006 inch)
(0.846 inch) (0.020 inch)
252-7959
252-7960 24.0 mm 0.5 mm 0.150 mm
261-0650 (0.945 inch) (0.020 inch) (0.006 inch)
278-8809 33.0 mm 0.5 mm 0.250 mm

(1.300 inch) (0.020 inch) (0.010 inch)
375-0114 33.0 mm 0.5 mm

(1.300 inch) (0.020 inch)
386-5921
24.0 mm 0.5 mm 0.150 mm
(0.945 inch) (0.020 inch) (0.006 inch)
0.150 mm
389-3912 21.5 mm 0.5 mm
(0.006 inch)
(0.846 inch) (0.020 inch)
Checklist for Inspection and Salvage of Front Wheel Spindles /

Front Axles
Reuse Inspection
Table 8
Critical Available Procedures for Salvage
Type of Check
Features
Entire spindle / Magnetic particle inspection (preferred) or dye Magnetic Particle Inspection of
front axle penetrant (optional) for cracks Front Spindles / Front Axles
The hardness for each journal must be at a
Rockwell rating of at least 30N 64. (Rockwell C
45)
Bearing journals The tolerance of the OD for each journal is
Refer to Table 4
+ 0.025 - 0.050 mm (+ 0.0010 - 0.0020 inch).
The alignment of each journal must be measured
to a tolerance of
± 0.025 mm (± 0.0010 inch).
Crack Detection Methods
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.
Inspection personnel can reference ASTM E165 and E709 for further details on inspection processes.
Personnel who perform examinations in accordance with this guide shall be qualified and certified.
Individuals must be certified for Magnetic Particle Inspection at a minimum Level I in accordance with
ASNT Recommended Practice No. SNT-TC-1A or ASNT CP-189.
Crack detection methods commonly used are liquid penetrant, dry magnetic particle, wet magnetic particle,
and ultrasonic testing. There may be more than one acceptable crack detection method for the inspection of a
given part, although the liquid penetrant is the most versatile. Select the method that best fits your shop's
operation. Sometimes, characteristics of a particular part may prevent the 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 9 to determine the best system for the type of structure being inspected. The wet magnetic particle
inspection method is best used when inspecting smooth machined components such as shafts, gear teeth, and
splines. If the wet magnetic particle inspection method is not available, it can be substituted with the liquid
penetrant examination method.
Table 9
Detection Methods vs. Material Structure
Type Of Structure
Inspection Method Nonferrous Ferrous
Liquid Penetrant X X
Dry Magnetic Particle − X
Wet Magnetic Particle − X
Ultrasonic Testing X X
Advantages and Disadvantages
Table 10
Advantages vs. Disadvantages
Detection System Advantages Disadvantages
Least expensive.
Minimal training required.
Least sensitive.
Liquid Penetrant Portable
Detects only surface cracks.
Works on nonmagnetic parts.
Dry Magnetic Particle Portable Works only on magnetic parts.

Fast Not as sensitive as fluorescent materials.
More sensitive than dry
Requires power for light.
powder.
Wet Magnetic Particle Works only on magnetic parts.
Detects subsurface as much
Liquid composition and agitation must be
as
monitored.
0.13 mm (0.005 inch).
Most sensitive.
Most expensive.
Ultrasonic Testing Detects deep material
Requires operator training and certification.
defects.
Liquid Penetrant Examination
Materials Required
• Cleaner: This removes dirt before dye application and dissolves the penetrant making it possible to
wipe the surface clean.
• Penetrating Oil: This solution is highly visible, and will seep into openings at the surface of a part with
capillary action.
• Developer: This provides a blotting action, bringing the penetrant out of the discontinuities and
providing a contrasting background to increase the visibility of the penetrant indications.
• Wire Brush
• Cloth
Procedure
1. Preclean inspection area. Spray on cleaner to loosen any scale, dirt, or any oil. Wipe the area to inspect
with a solvent dampened cloth to remove remaining dirt and allow the area to dry. If there is visible
crack remove paint using paint remover or wire brush.
2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to
soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.
3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow
the area to dry thoroughly.
4. Before using Developer make sure that it is mixed thoroughly by shaking can. Holding can
approximately 8-12 inches away from part, apply an even, thin layer of developer over the area being
inspected. A few thin layers are a better application method than one thick layer.
5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will
show as (A) red lines in white developer background. Clean the area of application of the developer
with solvent cleaner.
Dry Magnetic Particle Inspection
Materials and Equipment Required
• Crack Detection Kit
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(C) Dry powder bulb.
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.
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 lb).
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. Insure 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 Inspection
Materials and Equipment Required
• Crack Detection Kit
• UV Lamp Light
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(D) UV lamp used in wet/liquid magnetic particle inspection process.
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
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 50 met (5.0 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.
◾ Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 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 lb).
Procedure
1. Insure 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:
◦ 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. Due to the increased sensitivity resulting while the yoke is
energized, the yoke is not moved until the evaluation is completed in the first direction. An AC
yoke shall be used.
4. Visually inspect for indications of discontinuities using the proper illumination.
5. Record the size and shape of any discontinuities found.
Multiple Crack Criteria
Collinear if less than 45° angle.
(A) 45° angle.
Two cracks close together are considered to be collinear (along the same line) if the angle between the two
cracks is less than 45°.
Multiple Crack Criteria.
(1) Collinear within 25.0 mm (0.984 inch) diameter circle, treat as one crack.
(2) Collinear outside 25.0 mm (0.984 inch)diameter circle, treat as two cracks.
(3) Non-Collinear within 25.0 mm (0.984 inch) diameter circle, treat as two cracks.
(4) Mixture of Collinear and Non-Collinear within 25.0 mm (0.984 inch) diameter. Treat the two collinear cracks as one crack.
Treat the one non-collinear crack as one crack.
• After grinding is complete determine if multiple cracks are still present. Measure the area to determine
if the cracks fall within a 25.0 mm (0.984 inch) diameter circle.
• If multiple cracks are within the 25.0 mm (0.984 inch) they are considered as a single crack.
• If the effective crack length is greater than the allowable criteria for each zone, the spindle / front axle
must be sent to Reman for salvage process.
Note: Refer to ""Spindle / Front Axle Zones, Crack Inspection, and Repair of 793 & 797 Front
Spindles / Front Axles" " for spindle / front axle zones and crack criteria for each zone.
Example of Crack Separation.
Note: Circles represent 25.0 mm (0.984 inch) area.
• Example (5) is considered two separate cracks. The cracks are separated by a 25.0 mm (0.984 inch)
area.
• Example (6) is considered one continuous crack. The cracks are within a 25.0 mm (0.984 inch) area.
• Example (7) is considered one continuous crack. The two cracks span within a 25.0 mm (0.984 inch)
area.
Splines
Perform a complete inspection of the spline before you proceed with the repair procedure. During an
inspection, the best results can be achieved with the use of a magnifying glass and a strong light source.
Sunlight is the best light source. If it is difficult to distinguish small scratches from cracks, use either a liquid
dye penetrant or a magnetic particle inspection.
Inspect every spline on each spindle / front axle. If a damaged spline is found, recheck the spline on mating
parts. Then, inspect the teeth that are 180° from the damaged splined tooth for possible bending fatigue.
Crack Inspection for Splines

Thoroughly clean the splines before inspection occurs.
Typical Sequence in the Failure of a Spline
When you inspect a spline, determine whether the damage will progress into a failure before the next
scheduled overhaul. Analyze the application and spline size for each truck when you make this determination.
There are two typical sequences for a failure:
• Misalignment can cause spline wear. Spline wear can lead to a fracture.
• A fatigue crack can cause a fracture.
Wear and Misalignment
There is normally a small amount of relative motion between meshing spline teeth. Uneven contact patterns
on the spline teeth are the result of misalignment of one or both of the meshing splines. Splines that are
misaligned do not fully engage. This means that only a portion of each tooth is carrying the full load. If the
brake hub and the spindle / front axle are not aligned, the spline teeth will not mesh correctly. This situation
can place high contact pressures on a portion of the teeth. Misalignment can cause high contact pressure and
relative movement. Eventually, spline wear and fretting corrosion will appear as damage on the surface.
Misalignment can be identified by the uneven contact pattern on the spline teeth.
If any spline displays uneven contact patterns, be sure to check for misalignment and correct the cause of the
problem. The spline could be misaligned, if any of the following are worn or damaged.
Do not reuse a spline with damage from misalignment. Even if you correct the cause of misalignment, the
previous abnormal wear will not permit full tooth contact. Correct the cause of misalignment. Then install a
new spline.
Normal Wear
The spline shows signs of even loading and full contact.
USE AGAIN
Even though the area has a deep indentation, the spline is not cracked.
USE AGAIN
The spline in this illustration has an external wear step. This spline is reusable because the measurements are within the required
specification. Fretting corrosion is also apparent due to lack of lubrication. Fretting should not progress if the spline is reused.
USE AGAIN
Damage of Spline Teeth
A tooth on this spline is missing and the adjacent teeth are heavily damaged.
DO NOT USE AGAIN
This spline has a crack which began in the root. The crack has progressed into the adjacent splines.
DO NOT USE AGAIN
Pitting and Fretting
This spline shows heavy pitting.
DO NOT USE AGAIN
This spline has heavy fretting corrosion.
DO NOT USE AGAIN
Reusability of Splines
This section provides the procedures that are necessary for you to measure external splines. This section will
help you to calculate these measurements. These results can be used to determine reusability of external
splines.
Measuring Procedure
• For the measurement of an external spline, take three measurements over pins. For each of the three
dimensions, measure the highest external point over two pins that are 180° opposite of each other.
• Average the three dimensions in order to produce the average dimension over pins.
• Compare these measurements to Table 11 in order to determine the spline wear.
This external spline exhibits a typical wear step.
For this procedure, the spline will require the use of a specific pin set. There are three pin sets for the
measurement of splines. Each pin set consists of six pins. Each pin is machined to a specific dimension. Care
must be taken in order to precisely machine these pins to the specification due to the close tolerances of the
splines.
Make the pins out of SAE1020 steel. Use the dimension for the pin diameter in Table 11 to precisely machine
each pin for the specific pin set. Magnetize each pin so that the pins will stay in place during the process of
measurement. You may also use a rubber band to secure the pins. Refer to Illustration 43.
To measure an external spline, calculate the average for the three measurements over pins. Use the following
procedure to determine the maximum allowable spline wear.
Use an outside micrometer to measure external splines. To obtain accurate results, you must have a thorough
working knowledge of the use of outside micrometers.
Pins must be 60° from other pins. Refer to Illustration 44 and Illustration 45.
Place pins at 60° intervals. A rubber band is used to secure the pins.
The measurement of an external spline is shown here. Pins are located at 60° intervals.
Take three measurements (A), (B), and (C) over pins that are 180° across from each other. The outside micrometer must be
positioned in order to measure the highest two points over the pins. The next section will demonstrate the correct way to calculate
the average dimension over pins.
The measurement of an external spline is shown here. Pins are located at 60° intervals.
Verify that the spline is not out of round. This can be done by taking the maximum difference between the
high pin and the low pin. The next section provides examples for obtaining this measurement. This
measurement is a critical measurement which must be calculated in order to ensure that the spline can evenly
transfer a load.
Measurement Examples
External Spline
Place pins at 60° intervals on the spline. The location of the pins at 60° intervals is critical to the formula.
These three locations will provide information about the wear of the part. Refer to Illustration 45.
The following steps show the calculations that are required to check the measurements for an external spline.
1. Take measurements at location (A), location (B), and location (C). The measurements in the following
list are provided as an example.
◦ Dimension (A) is 416.250 mm (16.3878 inch).
◦ Dimension (B) is 416.500 mm (16.3976 inch).
◦ Dimension (C) is 416.750 mm (16.4074 inch).
2. Once measurements (A), (B), and (C) are obtained, add the measurements together.
◦ "Dimension (A) + (B) + (C) = 1249.500 mm (49.1928 inch)"
3. Divide this sum by 3 in order to obtain the average. The result is 416.500 mm (16.3976 inch).
4. Because this average is greater than 416.035 mm (16.3793 inch) (the specification for the minimum
reuse dimension over pins), the spline wear is acceptable.
5. Calculate the difference between the high measurement 416.750 mm (16.4074 inch) and the low
measurement 416.250 mm (16.38776 inch).
◦ "416.750 mm (16.4074 inch) - 416.250 mm (16.3878 inch) = 0.500 mm (0.0197 inch)"
The difference between the high dimension and the low dimension indicates whether the splines are out
of round. Never install a warped spline. A load cannot be distributed evenly on a spline that is out of
round. Teeth on a warped spline can crack due to excessive stress. The excessive stress is caused from
an uneven load distribution on the splines. The difference between the high measurement and the low
measurement will help to determine if the part can be used again.
The maximum dimension between the high dimension and the low dimension is 0.416 mm (0.0164
inch). Refer to Table 11 for this dimension. Because the actual difference 0.500 mm (0.0197 inch) is
greater than the allowable maximum, This spline is elliptical. DO NOT USE AGAIN
If the spline does not meet both specifications, do not reuse the spindle / front axle. An external spline
must pass both of the following tests in order to be used again.
• Minimum dimension over pins
• Maximum difference between the high dimension and the low dimension
Table 11
Reuse Dimensions for Splines on Spindles / Front Axles
Reman Minimum Print
Spindle / Front Axle Pin Minimum Reuse
Service Part Dimension Over Pins
Part Number Diameter Dimension Over Pins
244-7765, 10R-6185 8.000 mm

557.190 mm 556.643 mm
389-3912 N/A (0.31496
(21.93657 inch) (21.91503 inch)
inch)
8.000 mm
278-8809 10R-9958 638.115 mm
(0.31496
(25.12259 inch)
inch)
375-0114 20R-1696
8.000 mm 638.115 mm 637.560 mm
(0.31496 (25.12259 inch) (25.10074 inch)
inch)
Spindle / Front Axle Zones, Crack Inspection, and Repair of 793 &
797 Front Spindles / Front Axles
The following instruction explains the spindle / front axle zones and crack criteria for the 793 & 797
Front Spindles / Front Axles only.
View of 793 standard spindle / front axle and 797 spindle / front axle.
(A) Spindle / Front Axle Zone A and View of Threaded Holes.
(A2) 32.0 mm (1.260 inch) Elliptical Radius and Seal Surfaces for 793 standard spindles / front axles only.
(A2) 40.0 mm (1.575 inch) Elliptical Radius and Seal Surfaces for 797 spindles / front axles only.
(B) Spindle / Front Axle Zone B.
(B2) 60.0 mm (2.362 inch) Radius and Pilot Diameter for 793 standard spindles / front axles.
(B2) 75.0 mm (2.953 inch) Radius and Pilot Diameter for 797 spindles / front axles.
(F) Spindle / Front Axle Zone F (brake flange).
(K) Spindle / Front Axle Zone K
(R) Spindle / Front Axle Zone R.
• 16.0 mm (0.630 inch) of surface cracks are allowed in Zone (A). No cracks are allowed in the threaded
holes of Zone (A) that meet the Multiple Crack Criteria.
• If cracks exceed 16.0 mm (0.630 inch) the spindle / front axle must be sent to Reman for the salvage
process.
• No surface cracks are allowed in the (A2) 32.0 mm (1.260 inch) for 793 spindles / front axles and 40.0
mm (1.575 inch) for 797 spindles / front axles of Zone (A) .
• 16.0 mm (0.630 inch) of surface cracks are allowed in Zone (B) that meet the Multiple Crack Criteria
in Illustration 33.
• Grind cracks in Zone (B) to a depth of 5.0 mm (0.197 inch) and blend to a smooth radius of 12.0 mm
(0.472 inch). No cracks are allowed in Zone (B2) and Pilot Diameter.
View of 793 XLP spindle / front axle.
(A) Spindle / Front Axle Zone A and View of Threaded Holes.
(B) Spindle / Front Axle Zone B.
(F) Spindle / Front Axle Zone F (splined brake flange).
(K) Spindle / Front Axle Zone K
(R) Spindle / Front Axle Zone R.
• No surface cracks are allowed in Zone A or Zone B. If cracks are present, the spindle / front axle must
be sent to Reman for salvage process.
(T) Top and Bottom View of Spindle / Front Axle Zone T.
(T) Top and Bottom View of Spindle / Front Axle Zone T.
(S) Spindle / Front Axle Zone S
(S) Spindle / Front Axle Zone S
Zone T Crack Inspection
(T) Zone T Bottom Side.
(T1) 430.0 mm (16.929 inch) Diameter on the Mounting Face for 793 standard spindles / front axles only.
(T1) 500.0 mm (19.685 inch) Diameter on the Mounting Face for 797 spindles / front axles only.
• The mounting face should not be repaired if cracks on the (T1) are within 430.0 mm (16.929 inch) for
793 standard spindles / front axles and 500.0 mm (19.685 inch) for 797 spindles / front axles. If cracks
are visible submit the information to the Dealer Service Network for instructions.
• Cracks can be excavated by grinding to a maximum depth of 7.0 mm (0.275 inch) outside of the
mounting face in Zone (T). The spindle / front axle may be reused after grinding if the crack lengths are
less than 25.0 mm (0.984 inch) and meet the Multiple Crack Criteria listed in Illustration 33.
• Blend the surrounding surface with a smooth radius of 12.0 mm (0.472 inch) minimum.
(T) Zone T Bottom Side.
(T1) 495.0 mm (19.4881 inch) Diameter on the Mounting Face for 793 XLP spindles / front axles only.
• Cracks on the mounting face should not be repaired. If cracks are found, submit Dealer Service
Network for Engineering feedback.
(T) Zone T Top Side.
(H) Zone H Tapered Bore.
(T) Zone T Top Side.
(H) Zone H Tapered Bore.
• Cracks that appear in the top side machined surface of Zone (T) are allowed if the crack length is less
than 25.0 mm (0.984 inch) and meet the Multiple Crack Criteria listed in Illustration 33.
•
a smooth radius of R12 mm minimum.
• Grind 10.0 mm (0.393 inch) deep in rough cast areas of Zone (T) to remove cracks and blend the
surrounding areas to a smooth radius of R12 mm minimum.
• Grind cracks in Tapered Bore Zone (H) that are greater than 16.0 mm (0.629 inch) in length to a depth
of 7.0 mm (0.276 inch) maximum.
• Cracks that are less than 16.0 mm (0.629 inch) in length are allowed in Zone (H) if they meet the
Multiple Crack Criteria. Blend the surrounding surface with a smooth radius of R12 mm minimum.
• The entire area of Zone (H) should be cleaned and free of debris after repair.
Zone (R1) Top view.
Zone (R1) Top view.
Zone (R2) Side View.
(R3) 260.0 mm (10.236 inch) for 793 standard spindles / front axles only.
(R3) 300.0 mm (11.811 inch) for 797 spindles / front axles only.
(R3) 200.0 mm (7.874 inch)
(R3) 200.0 mm (7.874 inch)
• Grind cracks in Zone (R1) to a depth of 12.0 mm (0.472 inch) maximum in the top areas.
• Grind cracks in Zone (R2) to a depth of 12.0 mm (0.472 inch) within the side area of (R3) 260.0 mm
(10.236 inch) for 793 standard spindles / front axles, 200.0 mm (7.874 inch) for 793 XLP spindles /
front axles and 300.0 mm (11.811 inch) for 797 spindles / front axles.
• Grind cracks on previously ground surfaces to a depth of 3.0 mm (0.1181 inch) max.
• Use the same procedure for the opposite side. Blend the surrounding surface with a smooth radius of
12.0 mm (0.472 inch) minimum.
• After grinding is complete the spindle / front axle can be used again if the lengths of the cracks are less
than 25.0 mm (0.984 inch) and meet the Multiple Crack Criteria listed in Illustration 33.
• Craze or cluster cracking is allowed if they fall within the Multiple Crack Criteria.
Zone (R4) Bottom View.
Zone (R4) Bottom View.
• Grind cracks on the bottom side of Zone (R4) to a depth of 3.0 mm (0.118 inch) maximum on the cast
surface.
• Blend ground areas with surrounding surfaces to a radius of 12.0 mm (0.472 inch) minimum. No cracks
are allowed in this area after grinding.
• If cracks or indications are still present submit Dealer Service Network for Engineering feedback.
Zone (F) Brake Flange.
• Do not grind any cracks on Zone (F) Brake Flange surface.
• Cracks or indications are allowed on the outside diameter of Zone (F) if they are less than 25.0 mm
(0.984 inch) in length and do not extend through either of the adjacent surfaces.
• If cracks are found a Dealer Service Network must be submitted with the following information: (1)
The length and depth of the crack/s as per multiple crack criteria. (2) The location of the crack/s and the
distance from the mounting holes.
Zone (S)
Zone (S)
• Grind cracks in Zone (S) to a depth of 7.0 mm (0.275 inch) maximum.
• Blend ground areas with surrounding surfaces to a radius of 12.0 mm (0.472 inch) minimum.
• After grinding, the spindle / front axle is allowed to be used if the length of the crack/s are less than
25.0 mm (0.984 inch) and meet the Multiple Crack Criteria listed in Illustration 33.
• Craze or cluster cracking is allowed if they fall within the Multiple Crack Criteria.
Zone K Crack Inspection and Grinding Procedure

Note: Zone K does not apply on 793 XLP spindles / front axles.
Zone (K1)
• Cracks in Zone (K1) are allowed if the length of the cracks are less than 25.0 mm (0.984 inch) and
meet the Multiple Crack Criteria listed in Illustration 33.
• Cracks in Zone (K1) can be excavated by grinding to a depth of 7.0 mm (0.275 inch) maximum.
• Blend the surrounding surface with a smooth radius of 12.0 mm (0.472 inch) minimum.
• After grinding the spindle / front axle can be used again if the length of the crack/s are less than 25.0
mm (0.984 inch) and meet the Multiple Crack Criteria.
(K2) Machined Face.
(K3) Machined Face.
(K4) Crack in corner of Keyway.
(K5) Crack in corner of Keyway.
• Do not grind on Machine Faces (K2) and (K3). If cracks are present in these areas a DSN must be
submitted for Engineering Feedback.
Note: Before grinding on the Keyway determine if previous grinding has been performed. If grinding has
been performed proceed with the welding process. Refer to Section ""Weld Procedure for Zone K" ".
Depth of grind in corners of Zones (K4) and (K5) .
(L) 5.0 mm (0.1969 inch)
Grind cracks at the corners (K4) and (K5) to a depth of (L) 5.0 mm (0.197 inch) maximum. If cracks still
appear, proceed with the welding process. Refer to Section ""Weld Procedure for Zone K" ".
Additional Crack Grinding in Zone K
If cracks are still present after initial grinding to a depth of 5.0 mm (0.197 inch) grind an additional 5 mm
(0.197 inch) without affecting the slot width.
The following conditions must be met to continue with the weld procedure. Use the Magnetic Particle
Inspection procedure to verify the cracks.
1. Maximum length of the crack must be less than 108.0 mm (4.251 inch).
2. The depth of the crack must be less than (M) 10.0 mm (0.394 inch) total depth.
If the crack is still present beyond 10.0 mm (0.394 inch) or 108.0 mm (4.251 inch) in length the spindle /
front axle cannot be used again. Refer to Illustration 70 to determine crack depth and crack length.
(L) 5.0 mm (0.197 inch)
(M) 10.0 mm (0.394 inch)
Weld Procedure for Zone K

Note: The weld procedure and weld parameters in this section are used to repair deep cracks in the corner of
the key way in Zone (K.)
Weld Parameters
Use the direct current electrode positive polarity (DC reverse polarity) setting and remove the slag after every
pass. The weld width must not exceed two times the electrode diameter.
The FCAW process will be used with the E90T-1 D-3 (ANSI/AWS A5.29) welding electrode such as the
ESAB Dual Shield 150. The weld deposited by these electrodes must have the following mechanical
properties listed in Table 12.
Table 12
Tensile Strength 620 MPa (90 KSI)
Yield Strength 540 MPa (78 KSI)
Elongation 17%
Impact Toughness 20 FT LBF @-20F (27J @- 30C)
• Welding parameters will vary due to weld position and operator preference but may not vary more than
10%.
Table 13
Wire Feed Speed Voltage Approximate Amps

Min 150 IMP 27 190
OPT 250 IMP 30 300
Max 300 IMP 33 365
Note: Use welding grade 100% Carbon-Dioxide Shielding Gas. 45-55 cfh flow rate. 20-25 mm ID gas
nozzle.
Welding Cracks in Zone K

• Pre-heat the area to be welded to 204.4° C (400° F).
• Weld the area to be repaired using a pass width of no greater than 8.0 mm (0.315 inch).
• The final weld pass must be no greater than 3.0 mm (0.118 inch) above any finished surface. Refer to
Illustration 71.
• After welding is complete grind, polish, and, needle peen the repaired area.
• The repaired area must be finished to the original specifications. This area has critical functionality for
the mounting of the steering arm
View of 793 standard spindle / front axle.
Table 14
793
(N) Slot Width 152.76 ± 0.08 mm

(6.014 ± 0.003 inch)
(P) Slot Corner Chamfer 1.1 ± 0.5 mm

(0.043 ± 0.02 inch) X 45°
(R) Slot Fillet Radius 1.2 ± 0.5 mm

(0.047 ± 0.02 inch) X 45°
(S) Slot Depth 7.37 ± 0.25 mm

(0.290 ± 0.010 inch)
View of 797 spindle / front axle.
Table 15
797
(T) Slot Width 342.0 ± 0.02 mm

(13.464 ± 0.0008 inch)
(U) Slot Corner Chamfer 1.1 ± 0.2 mm

(0.043 ± 0.008 inch ) X 45°
(V) Slot Fillet Radius R1.2 ± 0.3 mm

(0.047 ± 0.012 inch)
(W) Slot Depth 7.37 ± 0.25 mm

(0.290 ± 0.010 inch)
• It is important to restore the repaired area to the specifications listed in Table 14 and 15, and
Illustrations 72 and 73.
• Use the ""Crack Detection Methods" " to verify the repair.
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Инструкция по повторному использованию шпинделей передних ступиц 785, 789

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Инструкция по повторному использованию шпинделей передних ступиц 785, 789

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789D Off-Highway Truck SPD00001-UP (MACHINE) POWERED BY 3516 Engine... Стр.

Reuse And Salvage Guidelines

Inspection and Salvage of Front Wheel Spindles for Off-Highway

Off-Highway Truck/Tractor: All

Information contained in this document is considered Caterpillar: Confidential Yellow.

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

This safety alert symbol means:

Your Safety is Involved.

Service Letters and Technical Information Bulletins

The most recent Service Letters and Technical Information Bulletins

Read and understand the manufacturer's instruction and your

Refer to the American National Standard Z49.1, "Safety in Welding

Standardized Parts Marking

Note: Use metal marking pen for all marking.

Checklist for Inspection and Salvage of Front Wheel Spindles /

Protective Equipment, Tools and Materials Needed

4C-4804 Penetrating Oil As needed

Outside Micrometer Set

Identification of Spindle / Front Axle Type

Typical front spindle/ front axle.

Typical front spindle / front axle.

Identification of Areas that Wear

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and warnings

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When

Typical burr removal tooling.

(A) Right Angle Die Grinder

(B) Die Grinder

(F) (G) Flapper Wheels

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

• Use appropriate thread taps to chase all threaded holes.

Wheel Bearing Journals

This is an inner journal that exhibits normal wear.

DO NOT USE AGAIN

This outer journal exhibits scratching and spalling damage.

DO NOT USE AGAIN

This is an outer journal that exhibits heavy damage from spalling.

DO NOT USE AGAIN

DO NOT USE AGAIN

This is an inner journal that exhibits scratching and spalling damage.

DO NOT USE AGAIN

DO NOT USE AGAIN

Typical example of performing a hardness test using 6V-6035 Hardness Tester.

Repair for Front Spindle / Front Axle Assembly

77.77 ± 0.013 mm 129.982 ± 0.013 mm

(4.7488 ± 0.0010 (5.4988 ± 0.0010

133.320 ± 0.025 mm 152.370 ± 0.025 mm

124.0 + 20.0 - 0.0

77.77 ± 0.013 mm 129.982 ± 0.013 mm

6G-6440 133.320 ± 0.025 mm 152.370 ± 0.025 mm

161.0 + 20.0 - 0.0

124.0 + 20.0 - 0.0

5T-2098 130.0 + 20.0 - 0.0

5T-6116 111.0 + 20.0 - 0.0

(5.2488 ± 0.0010 inch) (5.9988 ± 0.0010

133.320 ± 0.025 mm 152.370 ± 0.025 mm

260.3 ± 0.025 mm 317.45 ± 0.025 mm

167.97 + 20.0 - 0.0