Inspection and Thermal Spray Procedure of Differential Case and Components for Certain Models {0679, 3258, 3284} Caterpillar

Articulated Truck

725 (S/N: 3T91-UP; WWA1-UP; B1L1-UP; AFX1-UP)

725C (S/N: T261-UP; T271-UP; LFB1-UP; TFB1-UP)

725C2 (S/N: 2T31-UP; TA61-UP; 2L61-UP; TA71-UP)

730 (S/N: 3F31-UP; 3T31-UP; WWB1-UP; AGF1-UP)

730 EJECTOR (S/N: 3F41-UP; 3T41-UP; B1W1-UP)

730C (S/N: T281-UP; T291-UP; LFF1-UP; TFF1-UP)

730C EJECTOR (S/N: LFH1-UP; TFH1-UP)

730C2 (S/N: 2T41-UP; 2L71-UP; TA81-UP; TA91-UP)

730C2 EJ (S/N: 2T51-UP; 2L81-UP)

735 (S/N: 3F51-UP; 3T51-UP; WWC1-UP; B1N1-UP; AWR1-UP)

735B (S/N: L4D1-UP; GLG1-UP; T4P1-UP; E4R1-UP)

735C (S/N: JE61-UP; JE71-UP; LFJ1-UP; TFJ1-UP)

740 (S/N: WWD1-UP; AXM1-UP; B1P1-UP; DTX1-UP)

740 EJECTOR (S/N: 3F71-UP; 3T71-UP; B1R1-UP)

740 GC (S/N: 3F81-UP; 3T81-UP)

740B (S/N: L4E1-UP; GLH1-UP; T4R1-UP; E4S1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

740C EJECTOR (S/N: LFN1-UP; TFN1-UP)

745 (S/N: 3F61-UP; 3T61-UP; JHW1-UP; JHX1-UP)

745C (S/N: JE81-UP; JE91-UP; LFK1-UP; TFK1-UP)

D20D (S/N: 9MG1-UP)

D250B (S/N: 5WD1-UP)

D250D (S/N: 6NG1-UP)

D250E Series II (S/N: 4PS1-UP)

D25C (S/N: 9YC1-UP)

D25D (S/N: 1HK1-UP)

D300B (S/N: 4SD1-UP)

D300D (S/N: 5MG1-UP)

D300E Series II (S/N: 5KS1-UP)

D30C (S/N: 7ZC1-UP)

D30D (S/N: 3AJ1-UP)

D35-HP (S/N: 3FD1-UP)

D350C (S/N: 8XC1-UP)

D350D (S/N: 9RF1-UP)

D350E Series II (S/N: 2XW1-UP)

D35C (S/N: 2GD1-UP)

D400 (S/N: 1MD1-UP)

D400D (S/N: 8TF1-UP)

D400E Series II (S/N: APF1-UP; 8PS1-UP)

D40D (S/N: 2JJ1-UP)

D44 (S/N: 2LD1-UP)

D44B (S/N: 8SD1-UP)

D550 (S/N: 4RD1-UP)

D550B (S/N: 5ND1-UP)

Compact Wheel Loader

901C (S/N: W4T1-UP)

901C2 (S/N: YKY1-UP)

902 (S/N: 7ES1-UP)

902C (S/N: W5T1-UP)

902C2 (S/N: YKT1-UP)

903C (S/N: G931-UP; MW41-UP; W6T1-UP)

903C2 (S/N: MW81-UP; YKL1-UP)

903D (S/N: MZY1-UP)

906 (S/N: MER1-UP; 6ZS1-UP)

908 (S/N: TAR1-UP; 8BS1-UP)

914G (S/N: PDF1-UP; 7ZM1-UP; 9WM1-UP)

914G2 (S/N: KNP1-UP)

920 (S/N: 41J1-UP; 75J1-UP; 62K1-UP)

IT14G2 (S/N: ERP1-UP)

Integrated Toolcarrier

IT14G (S/N: FWL1-UP; 8ZM1-UP; KZN1-UP; 1WN1-UP)

IT18 (S/N: 7ZB1-UP; 9NB1-UP)

IT18B (S/N: 4ZD1-UP; 2NJ1-UP)

IT18F (S/N: 6ZF1-UP)

IT24F (S/N: 4NN1-UP; 6KN1-UP)

IT28 (S/N: 8JB1-UP; 2KC1-UP)

IT28B (S/N: 1HF1-UP; 1JK1-UP)

IT28F (S/N: 1JL1-UP; 3CL1-UP)

IT28G (S/N: WAC1-UP; EWF1-UP; 8CR1-UP; 9AR1-UP; DBT1-UP)

IT38F (S/N: 6FN1-UP; 5DR1-UP)

IT38G (S/N: 7BS1-UP; 1CW1-UP)

IT38G Series II (S/N: JAN1-UP; CSX1-UP)

IT38H (S/N: JNJ1-UP)

IT62G (S/N: AKP1-UP; 6PS1-UP)

IT62G Series II (S/N: AYA1-UP)

IT62H (S/N: M5G1-UP)

Landfill Compactor

816 (S/N: 57U1-UP)

816B (S/N: 15Z1-UP)

816F (S/N: 5FN1-UP; BMR1-UP)

816F Series 2 (S/N: BZR1-UP)

816K (S/N: LT61-UP; WNB1-UP; SLL1-UP; WCL1-UP)

826B (S/N: 58U1-UP)

826C (S/N: 87X1-UP)

826G (S/N: 7LN1-UP)

826G Series II (S/N: AYH1-UP)

826H (S/N: AWF1-UP; ZXT1-UP)

826K (S/N: 2321-UP; 2L31-UP; 2T61-UP; SET1-UP)

836 (S/N: 3RL1-UP; 7FR1-UP)

836G (S/N: BRL1-UP; 7MZ1-UP)

836H (S/N: BXD1-UP; XTR1-UP)

836K (S/N: B8H1-UP; T6X1-UP; L6Z1-UP; LWZ1-UP; TWZ1-UP)

Load Haul Dump

R1300 (S/N: 6QW1-UP)

R1300G (S/N: LJB1-UP; NJB1-UP)

R1300G Series II (S/N: RSL1-UP)

R1600 (S/N: 9XP1-UP; 9EW1-UP)

R1600G (S/N: 9YZ1-UP)

R1600H (S/N: 9SD1-UP)

R1700G (S/N: SBR1-UP; XBR1-UP; 8XZ1-UP)

R2900 (S/N: ZLK1-UP; 5TW1-UP)

R2900G (S/N: GLK1-UP; JLK1-UP; NLK1-UP)

R3000H (S/N: RCM1-UP; RCY1-UP)

Mini Hydraulic Excavator

302.5 (S/N: 4AZ1-UP)

304.5 (S/N: WAK1-UP)

Motor Grader

120 (S/N: E921-UP; E931-UP; E941-UP; E951-UP; E961-UP; Y9A1-UP; Y9B1-UP; Y9C1-UP; Y9D1-UP)

120G (S/N: 2AB1-UP; 4HD1-UP; 87V1-UP; 11W1-UP; 61W1-UP)

120H (S/N: 1241-UP; CAF1-UP; 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 6YN1-UP; 3GR1-UP; 9YR1-UP)

120K (S/N: SZN1-UP; JAP1-UP)

120K Series 2 (S/N: SZS1-UP; SZZ1-UP)

120M (S/N: PJB1-UP; B9C1-UP; R9C1-UP; NJD1-UP; B9N1-UP; CBS1-UP; B9W1-UP; D9W1-UP; RMY1-UP)

120M Series 2 (S/N: M921-UP; M9C1-UP; M9H1-UP; R9N1-UP; R9W1-UP)

12G (S/N: 3WC1-UP; 3PL1-UP; 61M1-UP)

12H (S/N: 1251-UP; XZJ1-UP; CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP; AMZ1-UP)

12K (S/N: JJA1-UP; SZP1-UP)

12M (S/N: B9F1-UP; B9R1-UP)

12M Series II (S/N: R9R1-UP)

130G (S/N: 7GB1-UP; 59K1-UP; 74V1-UP; 12W1-UP; 09Y1-UP)

135H (S/N: CBC1-UP; BDJ1-UP; 3YK1-UP; 7PM1-UP; 8WN1-UP; AMX1-UP)

14 (S/N: NN41-UP)

140 GC (S/N: W921-UP)

140G (S/N: 50H1-UP; 72V1-UP; 13W1-UP)

140H (S/N: 1261-UP; CCA1-UP; XZH1-UP; 2ZK1-UP; APM1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3FR1-UP; 3AS1-UP)

140K (S/N: JPA1-UP; SZL1-UP)

140K Series 2 (S/N: SZW1-UP)

143H (S/N: 1AL1-UP; APN1-UP)

14M (S/N: B9J1-UP; R9J1-UP)

14M Series 3 (S/N: E9S1-UP; N9S1-UP)

16 (S/N: EN51-UP; NN51-UP)

160G (S/N: 4JD1-UP)

160H (S/N: ASD1-UP; 9EJ1-UP; XZK1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; CCP1-UP; 3HR1-UP; 2HS1-UP)

160K (S/N: SZM1-UP; JBP1-UP)

163H (S/N: 5AK1-UP; ARL1-UP)

16G (S/N: 93U1-UP)

16H (S/N: 6ZJ1-UP; 3JR1-UP; ATS1-UP)

16M (S/N: B9H1-UP; R9H1-UP)

16M Series 3 (S/N: E9Y1-UP; N9Y1-UP)

18 (S/N: EN61-UP; NN61-UP)

18M Series 3 (S/N: N9A1-UP; E9W1-UP)

24 (S/N: E9Z1-UP; N9Z1-UP)

24H (S/N: 7KK1-UP)

24M (S/N: B931-UP; B9K1-UP)

Multi Terrain Loader

277C (S/N: KCC1-UP)

Off-Highway Truck/Tractor

69D (S/N: 9SS1-UP; 9XS1-UP)

73D (S/N: 9YS1-UP; 1GW1-UP)

768B (S/N: 79S1-UP)

768C (S/N: 02X1-UP)

769C (S/N: 01X1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)

770 (S/N: JND1-UP; M7W1-UP; BZZ1-UP)

770G (S/N: KD21-UP; RMA1-UP; TWA1-UP; RMD1-UP; KDH1-UP; ECM1-UP; ECX1-UP)

772 (S/N: RLB1-UP; RGK1-UP; J2M1-UP; 10S1-UP; 11S1-UP; 80S1-UP)

772B (S/N: 64W1-UP)

772G (S/N: KE31-UP; TWB1-UP; RME1-UP; RMH1-UP; LTS1-UP; KEX1-UP; LTX1-UP)

773 (S/N: 63G1-UP)

773B (S/N: 5SC1-UP; 63W1-UP)

773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP)

773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)

773F (S/N: EED1-UP; EXD1-UP)

776 (S/N: 14H1-UP; 14W1-UP)

776B (S/N: 6JC1-UP)

776C (S/N: 2TK1-UP)

776D (S/N: 5ER1-UP; AFS1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP; 3NF1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)

777E (S/N: KDP1-UP; KDZ1-UP)

777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)

777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)

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

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

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

785C (S/N: AP21-UP; 1HW1-UP; APX1-UP; 5AZ1-UP)

785D (S/N: DMC1-UP; MSY1-UP)

785G (S/N: SH21-UP; TRG1-UP; RTL1-UP)

786 (S/N: 81A1-UP)

789 (S/N: 9ZC1-UP)

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

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

789D (S/N: SP21-UP; SPD1-UP; SHH1-UP; TWP1-UP)

789G (S/N: TR21-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

793F (S/N: RB41-UP; SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

OEM POWERTRAIN (S/N: DTE1-UP)

Petroleum Transmission

TH35-E81 (S/N: TZM1-UP)

Pipelayer

587R (S/N: BXL1-UP)

Quarry Truck

771C (S/N: 3BJ1-UP)

771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)

773G (S/N: G731-UP; G771-UP; MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)

775B (S/N: 7XJ1-UP)

775D (S/N: 6KR1-UP; 8AS1-UP)

775E (S/N: BEC1-UP)

775F (S/N: EYG1-UP; DLS1-UP)

775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)

Soil Compactor

815 (S/N: 91P1-UP)

815B (S/N: 17Z1-UP)

815F (S/N: BKL1-UP; 1GN1-UP; 2BS1-UP)

815F Series 2 (S/N: BYN1-UP)

815K (S/N: SL91-UP; MBB1-UP; WCS1-UP; T1Y1-UP)

825B (S/N: 43N1-UP)

825C (S/N: 86X1-UP)

825G (S/N: 6RN1-UP)

825G Series II (S/N: AXB1-UP)

825H (S/N: ZHC1-UP; AZW1-UP)

825K (S/N: 2331-UP; 2L91-UP; 2T91-UP; SEE1-UP)

835 (S/N: 44N1-UP)

Track-Type Tractor

D5B (S/N: 22X1-UP; 23X1-UP; 24X1-UP; 25X1-UP; 26X1-UP)

D6D (S/N: 03X1-UP; 04X1-UP; 05X1-UP; 06X1-UP; 31X1-UP; 32X1-UP)

Transmission

TH55 - KRESS (S/N: KCH1-UP)

Underground Articulated Truck

AD30 (S/N: CXR1-UP; DXR1-UP; GXR1-UP)

AD40 Series II (S/N: 1YZ1-UP)

AD45 (S/N: BKZ1-UP)

AD45B (S/N: CXM1-UP; GXM1-UP)

AD55 (S/N: ANW1-UP; DNW1-UP; GNW1-UP)

AD55B (S/N: JNW1-UP)

AD60 (S/N: KNW1-UP; NNW1-UP)

AD63 (S/N: TNW1-UP)

AE40 Series II (S/N: BLW1-UP; 1ZZ1-UP)

Underground Drill

UD245 (S/N: DCX1-UP)

Vibratory Soil Compactor

CP-433E (S/N: CYE1-UP; CFK1-UP; ASN1-UP; BTY1-UP)

CP44 (S/N: MPC1-UP; M4P1-UP)

CS-423E (S/N: EAE1-UP)

CS-433E (S/N: MC21-UP; DAC1-UP; CFP1-UP; ASR1-UP; BTT1-UP)

CS433E (S/N: BWG1-UP; ASH1-UP; DCL1-UP; AST1-UP; CFX1-UP)

CS44 (S/N: M4C1-UP; M4S1-UP)

Wheel Dozer

814 (S/N: 90P1-UP)

814B (S/N: 16Z1-UP)

814F (S/N: BGF1-UP; 9DM1-UP)

814F Series 2 (S/N: BXG1-UP)

814K (S/N: LW41-UP; DMB1-UP; WCM1-UP; T1Z1-UP)

824 (S/N: 29G1-UP)

824B (S/N: 36H1-UP)

824C (S/N: 85X1-UP)

824G (S/N: 4SN1-UP)

824G Series II (S/N: AWW1-UP)

824H (S/N: ASX1-UP)

824K (S/N: 2T21-UP; 2L41-UP; 2341-UP; RWB1-UP)

830M (S/N: 41E1-UP)

834 (S/N: 43E1-UP)

834B (S/N: 7BR1-UP; 92Z1-UP)

834G (S/N: BPC1-UP; 6GZ1-UP)

834H (S/N: XDC1-UP; BTX1-UP)

834K (S/N: TW41-UP; L4Y1-UP; LWY1-UP; TWY1-UP)

844 (S/N: BBN1-UP; 2KZ1-UP)

844H (S/N: BTW1-UP)

844K (S/N: MBE1-UP; M4R1-UP; KLS1-UP; K4Y1-UP)

854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)

854K (S/N: 2211-UP; KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)

Wheel Loader

910F (S/N: 1YK1-UP; 2SS1-UP)

910G Series II (S/N: B9X1-UP)

910H (S/N: SAT1-UP)

916 (S/N: 2XB1-UP; 3SC1-UP; 5KC1-UP; 8GC1-UP)

918F (S/N: 5DL1-UP)

922B (S/N: 94A1-UP; 88J1-UP)

924F (S/N: 4YN1-UP; 5NN1-UP; 6MN1-UP; 7PN1-UP)

924G (S/N: DDA1-UP; EEB1-UP; RBB1-UP; WMB1-UP; AAN1-UP; 9SW1-UP; 3PZ1-UP)

924GZ (S/N: RTA1-UP; AAB1-UP; KTC1-UP; 6YW1-UP; WGX1-UP; DFZ1-UP; 3DZ1-UP)

924H (S/N: JTM1-UP; WEM1-UP; KLN1-UP; RRS1-UP; LKW1-UP)

924HZ (S/N: RCB1-UP; WLB1-UP; PED1-UP; JRL1-UP; JZZ1-UP)

924K (S/N: KW41-UP; ENC1-UP; LCD1-UP; HJF1-UP; PWR1-UP; SNZ1-UP)

926 (S/N: 1CB1-UP; 7TC1-UP)

926E (S/N: 8NB1-UP)

926M (S/N: LTE1-UP)

928F (S/N: 8AK1-UP; 2XL1-UP; 7YM1-UP)

928G (S/N: GMB1-UP; DJD1-UP; WLG1-UP; 6XR1-UP; 7SR1-UP)

928H (S/N: RSB1-UP)

928HZ (S/N: BYD1-UP; CXK1-UP)

930 (S/N: 8CB1-UP; 71H1-UP; 41K1-UP; 73U1-UP)

930G (S/N: TWR1-UP; TFW1-UP)

930H (S/N: DHC1-UP; FTD1-UP)

930K (S/N: T681-UP; DYB1-UP; EYE1-UP; HEG1-UP; FRK1-UP; P3K1-UP; RHN1-UP; TNY1-UP)

930M (S/N: WLF1-UP; KTG1-UP; F5K1-UP; J5K1-UP; HEY1-UP)

936F (S/N: 8AJ1-UP; 4TK1-UP; 9MK1-UP)

938F (S/N: 1KM1-UP; 2RM1-UP; 8SM1-UP; 7SN1-UP)

938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)

938G Series II (S/N: RTB1-UP; MSC1-UP; CRD1-UP; PHN1-UP; B9Y1-UP)

938H (S/N: MCC1-UP; MJC1-UP; JKM1-UP; LKM1-UP)

938K (S/N: W8K1-UP; SWL1-UP; REP1-UP; XXT1-UP; HFW1-UP)

938M (S/N: P5K1-UP; J3R1-UP)

944 (S/N: 87J1-UP)

944A (S/N: 43A1-UP; 58A1-UP)

950 (S/N: 90A1-UP; 15J1-UP; 73J1-UP; 49U1-UP)

950 GC (S/N: M5K1-UP; M5T1-UP)

950B (S/N: 31R1-UP)

950F (S/N: 7ZF1-UP; 6YG1-UP)

950F Series II (S/N: 4DJ1-UP; 5SK1-UP; 8TK1-UP; 2LM1-UP)

950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)

950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP; MXL1-UP; JLX1-UP)

950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)

950K OEM (S/N: DPT1-UP)

950L (S/N: TNS1-UP; LXX1-UP)

950M (S/N: KSA1-UP; EMB1-UP; ENE1-UP; XCJ1-UP; NHL1-UP; FTR1-UP; LCR1-UP; J1S1-UP)

950M Z (S/N: HE81-UP)

960F (S/N: 9ZJ1-UP; 4CL1-UP; 6XL1-UP; 1YM1-UP)

962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)

962G Series II (S/N: BTA1-UP; BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962H (S/N: N4A1-UP; SSA1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP; L5S1-UP; PCW1-UP)

962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)

962L (S/N: MTN1-UP; SXS1-UP)

962M (S/N: K881-UP; EJB1-UP; JYD1-UP; LSE1-UP; RKH1-UP; RCL1-UP; J2S1-UP; F2T1-UP)

962M Z (S/N: SA81-UP)

966 (S/N: EL91-UP; J8R1-UP; M7R1-UP; WLW1-UP)

966 XE (S/N: EL81-UP; MZN1-UP)

966A (S/N: 33A1-UP)

966B (S/N: 75A1-UP)

966C (S/N: 18B1-UP; 9KC1-UP; 78G1-UP; 76J1-UP; 25U1-UP)

966D (S/N: 7BB1-UP; 6ZC1-UP; 11D1-UP)

966E (S/N: 2FD1-UP)

966F (S/N: 4YG1-UP; 3XJ1-UP; 6FJ1-UP; 6ML1-UP)

966F Series II (S/N: 9YJ1-UP)

966G (S/N: AAH1-UP; HDH1-UP; 9RS1-UP; 3PW1-UP; 3SW1-UP; 8XW1-UP)

966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)

966H (S/N: BJ61-UP; A6D1-UP; RWE1-UP; RYF1-UP; A6G1-UP; A6J1-UP; TAL1-UP; CYR1-UP; FMW1-UP)

966K (S/N: PBG1-UP; A5S1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

966L (S/N: FSL1-UP; FRS1-UP)

966M (S/N: MD71-UP; EJA1-UP; R8D1-UP; LMM1-UP; KJP1-UP; L8R1-UP; GMS1-UP)

966M Series XE (S/N: FL21-UP; P6C1-UP; DZL1-UP; B8P1-UP; XCR1-UP)

966R (S/N: 58Z1-UP)

970F (S/N: 7SK1-UP; 9JK1-UP; 7PL1-UP)

972 (S/N: SM21-UP; W991-UP; FGD1-UP; M7P1-UP)

972 XE (S/N: TZ21-UP; E5F1-UP; MBY1-UP)

972G (S/N: TLA1-UP; 7LS1-UP; 8TS1-UP; AAW1-UP; 1EW1-UP; 6AW1-UP; 9GW1-UP)

972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)

972H (S/N: GTA1-UP; WLA1-UP; LCC1-UP; A7D1-UP; NPE1-UP; A7G1-UP; A7J1-UP; WXZ1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

972L (S/N: RFB1-UP; YJW1-UP)

972M (S/N: A781-UP; L8E1-UP; LSJ1-UP; GGN1-UP; WGN1-UP; M8W1-UP)

972M Series XE (S/N: AN31-UP; L9S1-UP; M5S1-UP; EDW1-UP; R1Z1-UP)

980 (S/N: L841-UP; MK81-UP; MK91-UP; 42H1-UP; WFY1-UP)

980 XE (S/N: XE31-UP; XMA1-UP)

980B (S/N: 89P1-UP)

980C (S/N: 2EB1-UP; 13B1-UP; 2XD1-UP; 63X1-UP)

980F (S/N: 8CJ1-UP; 3HK1-UP)

980F Series II (S/N: 5XJ1-UP; 4RN1-UP; 8JN1-UP)

980G (S/N: BGC1-UP; 9CM1-UP; 2KR1-UP; 2SR1-UP)

980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)

980H (S/N: PF81-UP; P8B1-UP; MHG1-UP; A8J1-UP; KZL1-UP; JMS1-UP)

980H Series 2 (S/N: MKP1-UP)

980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)

980L (S/N: D8Z1-UP)

980M (S/N: MK21-UP; WW31-UP; MGD1-UP; XDJ1-UP; KRS1-UP; N8T1-UP)

982 (S/N: W821-UP; MK71-UP; GYL1-UP; WFX1-UP)

982 XE (S/N: XE41-UP; YWC1-UP)

982M (S/N: MK61-UP; F9A1-UP; WMD1-UP; XDL1-UP; LRS1-UP; K1Y1-UP)

986H (S/N: 9861-UP; L8S1-UP)

986K (S/N: MH81-UP; NL81-UP; SWH1-UP)

988 (S/N: 87A1-UP)

988B (S/N: 50W1-UP; 62Y1-UP)

988F (S/N: 8YG1-UP)

988F Series II (S/N: 2ZR1-UP)

988G (S/N: BNH1-UP; 2TW1-UP)

988G Series RTCH (S/N: 1NZ1-UP)

988H (S/N: A7A1-UP; BXY1-UP)

988K (S/N: T8E1-UP; L8X1-UP; LWX1-UP; TWX1-UP)

988K XE (S/N: E8X1-UP; EWX1-UP)

990 (S/N: 7HK1-UP)

990 Series II (S/N: BCR1-UP; 4FR1-UP)

990H (S/N: BWX1-UP)

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)

991K (S/N: 5301-UP)

992C (S/N: 42X1-UP; 49Z1-UP)

992D (S/N: 7MJ1-UP)

992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)

992K (S/N: 8801-UP; KK21-UP; RM21-UP; KK41-UP; RM51-UP; H4C1-UP; ZMX1-UP)

993K (S/N: LWA1-UP; Z4D1-UP; Z8D1-UP; Z9K1-UP; Z4Z1-UP; Z8Z1-UP)

994 (S/N: 9YF1-UP)

994D (S/N: 3TZ1-UP)

994F (S/N: 4421-UP)

994G (S/N: BEH1-UP; 8FR1-UP)

994H (S/N: DWC1-UP)

994K (S/N: MM91-UP; MRK1-UP; SMX1-UP)

G916 (S/N: 5GD1-UP)

G926 (S/N: 1SD1-UP; 3TD1-UP)

G936 (S/N: 3HD1-UP; 4ND1-UP; 8ED1-UP)

Wheel Skidder

518 (S/N: 8ZC1-UP; 50S1-UP; 55U1-UP)

518C (S/N: 9HJ1-UP; 1CL1-UP)

522C (S/N: 2WL1-UP)

528 (S/N: 96C1-UP; 97C1-UP; 51S1-UP; 78W1-UP)

528B (S/N: 8SJ1-UP)

530B (S/N: 5BK1-UP)

535C (S/N: MCT1-UP)

Wheel Tractor-Scraper

611 (S/N: 6SZ1-UP)

613 (S/N: 71M1-UP)

613B (S/N: 5XF1-UP; 38W1-UP)

613C (S/N: 92X1-UP)

613C Series II (S/N: KEH1-UP; B6J1-UP; 8LJ1-UP; TJK1-UP; LCZ1-UP)

613G (S/N: DXA1-UP; ESB1-UP; YCB1-UP; DBE1-UP)

615 (S/N: 46Z1-UP; 47Z1-UP)

615C (S/N: 5TF1-UP)

615C Series II (S/N: 9XG1-UP; B6M1-UP)

621 (S/N: 37G1-UP; 23H1-UP)

623 (S/N: 26U1-UP; 52U1-UP)

627 (S/N: 50K1-UP; 54K1-UP; 68M1-UP; 69M1-UP)

627E (S/N: 6EB1-UP; 6FB1-UP; 6GB1-UP; 6HB1-UP; 3WJ1-UP)

627F (S/N: 4YK1-UP)

627G (S/N: DBD1-UP; AYK1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)

627H (S/N: LCT1-UP; DBW1-UP)

627K (S/N: WTC1-UP; WTN1-UP)

630A (S/N: 52F1-UP)

631A (S/N: 51F1-UP)

631B (S/N: 13G1-UP)

631C (S/N: 67M1-UP)

631D (S/N: 24W1-UP)

631E Series II (S/N: 1NB1-UP; 3ND1-UP)

631G (S/N: DFA1-UP; DXE1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP; M1W1-UP)

631K (S/N: WT41-UP; WT61-UP; WTR1-UP; WTW1-UP)

633 (S/N: 44J1-UP)

633C (S/N: 66M1-UP)

633D (S/N: 25W1-UP)

633E Series II (S/N: 2PS1-UP)

637 (S/N: 64M1-UP; 65M1-UP; 91N1-UP; 92N1-UP; 79P1-UP)

637B (S/N: 26R1-UP)

637D (S/N: 26W1-UP; 27W1-UP)

637E (S/N: 1JB1-UP; 1LB1-UP)

637G (S/N: CEH1-UP; CEJ1-UP; DFJ1-UP; AXT1-UP; DEX1-UP)

637K (S/N: WTS1-UP; WTT1-UP; WTX1-UP; WTY1-UP)

639D (S/N: 99X1-UP)

641 (S/N: 64F1-UP; 41M1-UP)

641B (S/N: 65K1-UP)

650 (S/N: 63F1-UP)

651 (S/N: 33G1-UP; 44M1-UP; WSR1-UP)

651B (S/N: 67K1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP; 89Z1-UP)

657 (S/N: 31G1-UP; WSJ1-UP; WSM1-UP; 46M1-UP)

657B (S/N: 47M1-UP)

657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP; A4G1-UP; DXG1-UP; GER1-UP; GRS1-UP)

660 (S/N: 90F1-UP)

666 (S/N: 32G1-UP; 64H1-UP)

666B (S/N: 66K1-UP)

Introduction

Table 1

Revision	Summary of Changes in SEBF8119
29	Added new serial number prefixes Updated Table 4
28	Added 9 new serial number prefixes Added new part number 466-3320 to table 4. Updated Illustrations 9 and 20.
27	The information contained in SEBF2147 "Thermal Spray Procedures for Differential Case - Housing Face & Pinion Thrust Face" has been moved and combined with , SEBF8119. Added new part numbers to Table 4. Updated Illustration 9.
26	Changed title from "Differential Housing Components for Wheel Loaders, Articulated Trucks, Wheel Tractors, Compactors, Integrated Toolcarriers, and Motor Graders" to "Inspection and Thermal Spray Procedure of Differential Case and Components for Certain Models" Added 23 new serial number prefixes for New Product Introduction (NPI) and Revised effectivity list to individual serial number prefixes. Revised and Formatted Illustrations 8 and 24. Revised and Formatted Tables 1, 2, 3, 4, 5,6,7, 8, and 9. The information contained in SEBF2146 "Thermal Spray Procedures for Wheel Loaders, Off-Highway Trucks and Tractors, Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers Differential - Support Bearing Journal" and , SEBF2148 "Thermal Spray Procedures for Wheel Loaders, Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers Differential Case - Flange End" has been moved and combined with , SEBF8119.
25	Added new serial number prefixes for New Product Introduction (NPI).
24	Added new serial number prefixes for New Product Introduction (NPI). Added 1 part number.
23	Removed sleeving verbiage.

© 2020 AVSpare 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 AVSpare: 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 AVSpare dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to AVSpare. 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 AVSpare.

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.

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. AVSpare 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 AVSpare 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.

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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.

Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

AVSpare 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. AVSpare dealers can supply the most current information.

Summary

The contents of this guideline discuss the reusability of components of the differential housing for differentials. The contents also provide dimensions of diameters to reuse bearing journals. Differential housing assemblies can be salvaged by metal spraying pinion bores, bearing journals, axle bores, bearing shoulders, ring gear mounting faces, and split faces. Bolt hole damage and distortion in the flange half can be repaired by sleeving the bolt holes. The repair procedure in this guideline provides a method to salvage differential housings.

Several conditions can cause damage. For example, the differential housing bores can be damaged by foreign material or component failure. Damage to the differential housing can occur from bearing or gear failures. These failures can cause the bores of the housing to become elongated. Damage to the differential housing can also occur when subjected to extreme axial loads.

This guideline identifies the various areas that can be salvaged using the metal spray. The metal spray operation must be followed by precision machining and using dimensions provided in this guideline.

Differential housings that meet these salvage guidelines and specifications can be expected to perform normally in the same application. Never install a part that this guideline indicates cannot be used again. Before installing a used or reconditioned part, correct any condition that may have caused the original wear.

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.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have understood the operation, lubrication, maintenance, and repair information. If a part has met the specification in this guideline, the part can be expected to give normal performance until the next overhaul. The conditions apply when the part is used in the same application.

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.

References

Table 2

References
Media Number	Publication Type & Title
Channel1	"Gear Tooth Inspection"
	https://channel1.mediaspace.kaltura.com/media/Gear+Tooth+Inspection/1_5ujdi5zp
	"Why Reuse and Salvage Parts"
	https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
PERJ1017	Special Publication "Dealer Service Tools Catalog"
SEBF8187	Reuse and Salvage Guidelines "Standardized Parts Marking Procedures"
SEBF8193	Reuse and Salvage Guidelines "Reusability of Drive Train Gears"
SEBF8227	Reuse and Salvage Guidelines "Salvage of Differential Housing Assembly Used on Off-Highway Trucks"
SEBF8728	Reuse and Salvage Guidelines "Specifications for Inspection of Drive-line Fasteners"
SEBF9238	Reuse and Salvage Guidelines "Fundamentals of Arc Spray for reconditioning Components"
SEBF9240	Reuse and Salvage Guidelines "Fundamentals of Flame Spray for Reconditioning Components"

Service Letters and Technical Information Bulletins

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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.

Tooling and Equipment

Note: The Tooling and Equipment in Table 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.

Table 3

Required Tooling and Equipment
Part Number	Description	Designation
— (1)	Personal Protective Equipment (PPE)	Personal Protection
— (2)	Clevis/ Shackle	Component Repositioning and Movement
— (2)	Lifting Eye Assemblies	Component Repositioning and Movement
— (2)	Tool (Cribbing)	Component Repositioning and Movement
—	Suitable Lifting Device	Component Repositioning and Movement
1U-7262	Telescoping Magnet	General Tooling
4S-9405	Caliper 304.8 mm (12.00 inch)	Profile Measurement
5P-3920	Tool Rule 304.8 mm (12.00 inch)	Measurement Checks
8H-8581	Feeler Gauge 0.038 - 0.635 mm (0.0015 - 0.0250 inch)	Thickness Measurement Checks
1P-3537	Dial Bore Gauge Group	Internal Measurement Checks
385-9422	Tools (Micrometer) Internal (2 - 24 inch)	Internal Measurement Checks
386-3364	Tool (Ruler) 1,000.0 mm (39.37 inch)	Measurement Checks
431-4150	Micrometers External 0 - 25 mm (0 - 1 inch)	External Measurement Checks
473-8688 or 473-8689	Instrument Group Micrometer, Inside 2.00 - 12.00 inch	Internal Measurement Checks
	Instrument Group Micrometer, Inside 50 - 300 mm
473-8690	Instrument Group Micrometer, Outside 0.00 - 4.00 inch	External Measurement Checks
473-8691	Instrument Group Micrometer, Outside 2.00 - 6.00 inch	External Measurement Checks
473-8692	Instrument Group Micrometer, Outside - Digital 152.4 - 304.8 mm (6.00 - 12.00 inch)	External Measurement Checks
474-3709 or 474-3710	Instrument Group Micrometer, Inside (8.00 - 32.00 inch)	Internal Measurement Checks
	Instrument Group Micrometer, Inside 200 - 800 mm
— and /or —	GO/NO-GO Thread Gauge Set, Metric	Threaded Hole Inspection
	GO/NO-GO Thread Gauge Set, SAE
— (2)	Plastic Plug Assortment	Threaded Hole Protection
— (2)	Tap and Die Set	Threaded Hole / Restore
154-9316	File Metric	Threaded Shaft / Restore
1U-5516	Disc (Coarse)	Surface Preparation / De-burring
1U-5518	Threaded Shaft	Surface Preparation / De-burring
1U-5519	Holder (Disc Pad)	Surface Preparation / De-burring
4C-8514	Wheel (2 x 1 inch) (60 Grit)	Surface Preparation / De-burring
4C-8515	Grinding Wheel (F-Grade) (2 x 1 inch) (120 Grit)	Surface Preparation / De-burring
4C-8521	Wheel Adapter (.25 x 4.0 inch)	Surface Preparation / De-burring
222-3076	Die Grinder (Right Angle)	Surface Preparation / De-burring
254-5319	Brush 76.2 x 50.8 mm (3.00 x 2.00 inch)	Surface Preparation / De-burring
9U-7377 (3)	Metal Marking Pen	Parts Marking
6V-2010	Polishing Stone	Gear Polishing
1U-9918	Brush	General Cleaning
467-0158	Abrasive Material (Roll)	General Cleaning
8T-7765	Surface Reconditioning Pad (180 Grit)	General Cleaning
162-5791	Towel	General Cleaning
8T-5096	Tool Group Dial Indicator	Run-Out Checks
9S-8903	Indicator Contact Point	Run-Out Checks
5P-1720	Seal Pick	Gear/ Shaft Step Inspection
5P-7414	Seal Pick	Gear/ Shaft Step Inspection
170-5903	Gear Inspection Stand Group	Gear/ Spline Wear Inspection
1U-9978	Brush	Paste Application
7M-7456	Bearing Mount Compound	Bearing Installation
9A-1593	Comparison Gauge (Surface Texture)	Surface Texture Tester
453-5376	Tool Specimen	Surface Texture Tester
448-3698	Indicator (Profilometer)	Surface Texture Tester
458-9587 (4)	Paint Yellow	Touch Up
479-5400 (5)	Paint Yellow	Touch Up
8S-2257	Magnifying Glass	Visual Testing (VT)
9U-6182	Mirror (Telescoping)	Visual Testing (VT)
4C-9442	Light	Visual Testing (VT)
9U-7231	Flashing Lights Conversion Kit	Visual Testing (VT)
238-8244	Light-Pen	Visual Testing (VT)
269-3123	Leak Detector Light-Pen Blue	Visual Testing (VT)
—	Reflective Surface for Inspection	Visual Testing (VT)
262-8390	Microscope (40-Power) Pocket	Crack/ Measurement Inspection
1U-9367	Automatic Tape Measure (1-inch X 26- ft) 25.4- mm x 8- m	Visual Testing (VT)
288-4209	Paper Towel	Liquid Penetrant Testing (PT)
1U-9915	Brush Curved Handle Wire	General Cleaning/ Liquid Penetrant Testing (PT)
—	Developer	Liquid Penetrant Testing (PT)
—	Penetrating Oil	Liquid Penetrant Testing (PT)
—	Solvent Cleaner	General Cleaning/ Liquid Penetrant Testing (PT)
263-7184	Crack Detection Kit (Magnetic Particle)	Dry Magnetic Particle Testing (MT)
—	Paint Pen	Dry Magnetic Particle Testing (MT)
459-0184	Lamp Group Ultraviolet	Wet Magnetic Particle Testing (MT)
505-8671	Fluid Ultrasonic Wear Indicator	Ultrasonic Testing (UT)
415-4055	Tool Group(Ultrasonic)	Ultrasonic Testing (UT)

(1)	Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
(2)	Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
(3)	Available in the United States only.
(4)	Available in North and South America (except Canada).
(5)	Available in Canada, APD, and EAME.

Preparation Before Inspection

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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.

Illustration 3	g03794147
Typical burr removal tooling. (A) Right Angle Die Grinder (B) Die Grinder (C) Conditioning Discs, Disc Pad Holder, and Threaded Shaft (D) Flapper Wheels

• Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and oil.

• When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all lifting devices must be inspected before use.

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

• If the bore cannot be inspected immediately after cleaning, put hydraulic oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.

• Use appropriate thread taps to chase all threaded holes.

All components need thoroughly cleaned prior to inspection to be sure that no damage is hidden by oil or dirt. Use a wash tank or a coarse bristle brush with a mild petroleum-based solvent. Be sure that the solvent does not have any water contamination. Also, never use a chlorinated solvent. Water or chlorine can cause corrosion on the surface from pitting. Pits cause areas of highly concentrated stress that are called stress raisers to occur. These areas are more likely to result in component failure.

A magnifying glass and seal pick are useful in the close inspection of irregularities on the surface of the component. Use liquid penetrant testing or other suitable non-destructive testing equipment to check all components for cracks, and scrap any cracked parts. Emery cloth or abrasive sheets are used to remove surface rust, light fretting, or nicks from handling. When inspection is completed, be sure to maintain the cleanliness of all acceptable differential components and protect the components from moisture. If necessary, clean the parts again before reassembly.

Standardized Parts Marking Procedure

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part.

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NOTICE
Do not use numbering stamp punches to mark internal components. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure.

Illustration 4	g06124077
DO NOT use numbering stamp punches to mark internal components.

The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.

Example 1

Illustration 5	g03856853
Typical Example

Illustration 5 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.

Example 2

Illustration 6	g03856857
Typical Example

Illustration 6 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 gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 6. In this example, the gear has a total of 22,000 hours.

Example 3

Illustration 7	g03519882
Typical Example

(A) Mark the planet pin on either end.

Differential Housing Components

Illustration 8	g06455418
Differential Case Components (1) Housing Differential Flange Half (2) Ring Gear (3) Pinion Gear (4) Pin (5) Spider Gear (6) Housing Differential Plain Half

Refer to "References" section for additional information on inspection of gears.

Ring Gear and Pinion

On most machines, the ring and the pinion are serviced separately. However, if the ring and the pinion are a matched set, damage to either gear requires the installation of a new set.

Pitting of the Teeth

Start of Active Profile

If pitting of the teeth occurs on the ring gear and the pinion, the result is normally a line of small pits at the start of active profile. The pitting starts first on the pinion, and then on the ring gear. Refer to Illustrations 10 through 12.

Illustration 9	g06534806
Profile of Gear Tooth (1) Start of Active Profile (2) Pitch Line

Illustration 10	g01363842
Typical example of slight indication of pitting at the start of the active gear tooth profile.

OK TO USE PART AGAIN

Illustration 11	g01367967
Slight indication of pitting at the start of active profile.

OK TO USE PART AGAIN

Illustration 12	g03782673
Slight indication of pitting at the start of active profile

Pitch Line

If there is any pitting around the pitch line of a gear, then

DO NOT USE PART AGAIN

Differential Spider Gears, Side Gears, and Pinions

Surfaces of the thrust face must be free of smearing, grooves, corrosion from pitting and any other mechanical damage that could act as a cutting edge against the bearing.

Illustration 13	g01234759
The thrust face of the side gear has shallow grooves.

DO NOT USE PART AGAIN

Illustration 14	g01234768
Typical example of stains from rusting.

Part can be reused after removing the rust with a fine abrasive cloth.

OK TO USE PART AGAIN

Illustration 15	g01234825
Typical example of when the thrust face has been grooved by abrasive particles.

DO NOT USE PART AGAIN

Illustration 16	g01234832
Typical example of when the thrust face has been pitted by corrosion.

DO NOT USE PART AGAIN

Spider Shaft

No wear is permitted on spider shafts.

Differential Housing

Visually determine if the differential housing can be salvaged. Damage to machined bolt holes in the flange area may be repaired by enlarging the hole and installing a sleeve.

Illustration 17	g03704110
Inspect all areas indicated by arrows for wear, dents, nicks, and other types of damage.

• Check bolt hole depth using the bolt without the washer. The bolt must go completely through both parts with sufficient clearance for locknut, washer, and nut.

• Check the housing for cracks. If the housing is cracked, then DO NOT USE PART AGAIN.

• Check housing for heat damage and distortion.

• Check bore and outside diameter bearing surfaces for wear. If worn beyond recommended specification, repair the damage before using again.

Mounting Faces

Movement between the halves of the differential housing and between the ring gear and the housing causes the pieces to fret. Fretting refers to the wearing and transferring of metal between the pieces. Any parts that show fretting up to the amount in Illustration 18 can be reused after all high spots are removed. Face off the surface and build up the surface by thermal spray if the damage is deeper. Contact dealer support for dimensions for given parts.

Illustration 18	g01234839
The damage from fretting on the mounting surface is not excessive. The damage from fretting on the mounting surface must not be more than the amount of damage that is shown here.

OK TO USE PART AGAIN

Bore of the Spider Shaft

Some fretting is permitted in this bore. Refer to Illustration 19 for a typical example of acceptable fretting. The bores which are machined in the mounting face of the case may show fretting or wear beyond this point. The bores may then be built up using thermal spray and rebored. This is done together with the mounting faces. Contact Dealer Solutions Network (DSN) to obtain this dimension for given housings.

Illustration 19	g01234842
Typical example of acceptable fretting.

OK TO USE PART AGAIN

Housing Face and Pinion Thrust Face

Illustration 20	g06534814
Typical example of a Differential Case (A) Housing Face Halves (B) Side Gear and Piston Thrust Face

Side Gear and Pinion Thrust Faces

Do not reuse a housing if the thrust bearing has worn into the housing more than 0.5 mm (0.02 inch). Refer to Illustration 21. No welding on the ductile iron differential half and surfaces that are worn beyond the maximum amount can only be metal sprayed.

Illustration 21	g03782677
The thrust face does not have more than 0.5 mm (0.02 inch) wear.

The component is acceptable to be reused if the thrust face does not have more than 0.5 mm (0.02 inch) of wear.

OK TO USE PART AGAIN

Locating Dowel for the Thrust Bearing

Do not reuse a housing if the locating dowel is loose. Refer to Illustration 22. Loose dowels will break during operation, which will permit the thrust bearing to turn. Housings with worn dowel holes can be salvaged by drilling a new hole in the other half of the housing or by boring the worn hole, plugging the hole with a steel rod, and drilling a new hole in the original location.

Illustration 22	g01234855
Housing with loose locating dowel.

The hole for the locating dowel must be relocated or repaired to be reused before it is OK TO USE THE DIFFERENTIAL HOUSING AGAIN.

Support Bearing Journals

The maximum amount of wear that is permitted on the outside diameter of the bearing journals that support the differential housing is shown in Table 4. Journals that are worn beyond this amount can be salvaged with metal spray. Bearings that will be used on journals that are smaller than the new diameter must be installed using 7M-7456 Bearing Mount Compound. Wear on the thrust face up to 0.25 mm (0.010 inch) can be machined. Thrust surfaces that are worn beyond 0.25 mm (0.010 inch) can be built up with welding or thermal spray and can be remachined to the original dimensions that are provided in the charts.

Illustration 23	g01234859
Excessive wear on the bearing journal that supports the differential housing.

The bearing journal that supports the differential housing must be repaired.

OK TO USE PART AGAIN

Illustration 24	g06448867
Typical group of a differential housing (A) Bearing journal on the flange end (B) Bearing journal on the plain end

Table 4

Bearing Journal that Supports the Differential Housing Acceptable Dimensions and Tolerances
Part Number(1)	A	B
1V-5085 3K-4176 7V-7793	Ø 82.625 ± 0.015 mm (3.2529 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2529 ± 0.0006 inch)
1V-5868	Ø 104.826 ± 0.013 mm (4.1270 ± 0.0005 inch)	Ø 110.038 ± 0.013 mm (4.3322 ± 0.0005 inch)
1V-5869	Ø 127.076 ± 0.01270 mm (5.0030 ± 0.0005 inch)	Ø 110.038 ± 0.013 mm (4.3322 ± 0.0005 inch)
1V-6318	Ø 170.066 ± 0.020 mm (6.6955 ± 0.0008 inch)	Ø 133.426 ± 0.020 mm (5.2530 ± 0.0008 inch)
1V-6983 8K-7581	Ø 82.625 ± 0.015 mm (3.2529 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2529 ± 0.0006 inch)
2A-6708 8V-9808	Ø 110.88 ± 0.015 mm (4.3654 ± 0.0006 inch)	Ø 85.050 ± 0.015 mm (3.3484 ± 0.0006 inch)
2G-2630	Ø 114.437 ± 0.021 mm (4.5053 ± 0.0008 inch)	Ø 133.426 ± 0.020 mm (5.2530 ± 0.0008 inch)
2G-6020	Ø 63.500 mm (2.5000 inch)	Ø 63.500 mm (2.5000 inch)
2G-9200 6G-7560	Ø 139.857 ± 0.02 mm (5.5062 ± 0.0008 inch)	Ø 133.507 ± 0.02 mm (5.2562 ± 0.0008 inch)
2V-3954 9C-8278	Ø 104.825 ± 0.015 mm (4.1269 ± 0.0006 inch)	Ø 110.025 ± 0.015 mm (4.3317 ± 0.0006 inch)
2V-4419 7K-9308	Ø 114.437 ± 0.021 mm (4.5053 ± 0.0008 inch)	Ø 133.426 ± 0.020 mm (5.2530 ± 0.0008 inch)
3D-9561 6D-8531 6D-8540	Ø 139.857 ± 0.02 mm (5.5062 ± 0.0008 inch)	Ø 133.426 ± 0.02 mm (5.2530 ± 0.0008 inch)
3K-9516	Ø 127.076 ± 0.015 mm (5.0030 ± 0.0006 inch)	Ø 110.038 ± 0.013 mm (4.3322 ± 0.0005 inch)
4D-5630 4D-5730 6D-0736	Ø 114.376 ± 0.020 mm (4.5030 ± 0.0008 inch)	Ø 133.469 ± 0.02 mm (5.2547 ± 0.0008 inch)
4E-0699	—	Ø 75.038 ± 0.015 mm (2.9543 ± 0.0006 inch)
4E-0885	—	Ø 75.038 ± 0.015 mm (2.9543 ± 0.0006 inch)
4E-3191	Ø 88.977 ± 0.013 mm (3.5030 ± 0.0005 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
4E-6104 8R-7834	Ø 96.913 ± 0.015 mm (3.8155 ± 0.0006 inch)	Ø 85.800 ± 0.015 mm (3.3779 ± 0.0006 inch)
4V-4076	Ø 127.076 ± 0.015 mm (5.0029 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
4V-5391 6W-1631	Ø 90.056 ± 0.015 mm (3.5455 ± 0.0006 inch)	Ø 85.050 ± 0.015 mm (3.3484 ± 0.0006 inch)
4V-6451	Ø 77.838 ± 0.013 mm (3.0645 ± 0.0005 inch)	Ø 77.838 ± 0.013 mm (3.0645 ± 0.0005 inch)
4V-8733 8R-7922 8R-7926 9V-9486	Ø 114.375 ± 0.015 mm (4.5029 ± 0.0006 inch)	Ø 117.550 ± 0.015 mm (4.6279 ± 0.0006 inch)
5D-5580	Ø 110.0633 ± 0.02 mm (4.3332 ± 0.0008 inch)	Ø 115.1636 ± 0.02 mm (4.5340 ± 0.0008 inch)
5T-1030	Ø 152.588 ± 0.02 mm (6.0074 ± 0.0008 inch)	Ø 152.512 ± 0.02 mm (6.0044 ± 0.0008 inch)
5V-1272	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
5V-2756 8D-2669	Ø 90.030 ± 0.013 mm (3.5445 ± 0.0005 inch)	Ø 85.0316 ± 0.013 mm (3.3477 ± 0.0005 inch)
5V-5630	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
5V-9322	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
6G-7560	Ø 139.857 ± 0.02 mm (5.5062 ± 0.0008 inch)	Ø 133.507 ± 0.020 mm (5.2562 ± 0.0008 inch)
6G-7565	Ø 139.857 ± 0.02 mm (5.5062 ± 0.0008 inch)	Ø 133.4262 ± 0.02 mm (5.2530 ± 0.0008 inch)
6K-5626	Ø 77.838 ± 0.013 mm (3.0645 ± 0.0005 inch)	Ø 77.838 ± 0.013 mm (3.0645 ± 0.0005 inch)
6K-7636 6K-8381	Ø 104.851 ± 0.015 mm (4.128 ± 0.0006 inch)	Ø 110.052 ± 0.015 mm (4.3328 ± 0.0006 inch)
6S-3026	Ø 75.044 ± 0.013 mm (2.9545 ± 0.0005 inch)	Ø 75.044 ± 0.013 mm (2.9545 ± 0.0005 inch)
6S-7582	Ø 75.044 ± 0.013 mm (2.9545 ± 0.0005 inch)	Ø 75.044 ± 0.013 mm (2.9545 ± 0.0005 inch)
6W-1565	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
6W-2968 8V-2958	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
6W-3413	Ø 90.056 ± 0.015 mm (3.5455 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
6W-8261 120-0551 358-7234	Ø 152.505 ± 0.015 mm (6.0041 ± 0.0006 inch)	Ø 139.810 ± 0.015 mm (5.5043 ± 0.0006 inch)
7D-5013	Ø 127.076 ± 0.015 mm (5.003 ± 0.0006 inch)	Ø 110.038 ± 0.013 mm (4.3322 ± 0.0005 inch)
7D-7660	Ø 114.437 ± 0.021 mm (4.5053 ± 0.0008 inch)	Ø 133.469 ± 0.02 mm (5.2547 ± 0.0008 inch)
7K-4071	Ø 114.376 ± 0.013 mm (4.5030 ± 0.0005 inch)	Ø 114.376 ± 0.013 mm (4.5030 ± 0.0005 inch)
7V-2188	Ø 75.050 ± 0.015 mm (2.9547 ± 0.0006 inch)	Ø 75.050 ± 0.015 mm (2.9547 ± 0.0006 inch)
7V-9623	Ø 90.069 ± 0.015 mm (3.5460 ± 0.0006 inch)	Ø 96.932 ± 0.015 mm (3.8162 ± 0.0006 inch)
8D-0180	Ø 110.0633 ± 0.02 mm (4.3332 ± 0.0008 inch)	Ø 115.1636 ± 0.02 mm (4.5340 ± 0.0008 inch)
8D-4300	Ø 100.0633 ± 0.020 mm (3.9395 ± 0.0008 inch)	Ø 85.065 ± 0.020 mm (3.3490 ± 0.0008 inch)
8D-5620	Ø 139.857 ± 0.02 mm (5.5062 ± 0.0008 inch)	Ø 133.4262 ± 0.02 mm (5.253 ± 0.0008 inch)
8D-9890	Ø 65.062 ± 0.020 mm (2.5615 ± 0.0008 inch)	Ø 63.500 mm (2.5000 inch)
8K-5992	Ø 82.601 ± 0.013 mm (3.252 ± 0.0005 inch)	Ø 82.601 ± 0.013 mm (3.252 ± 0.0005 inch)
8K-6507 8K-7437 9K-5654	Ø 82.601 ± 0.013 mm (3.2520 ± 0.0005 inch)	Ø 82.601 ± 0.013 mm (3.2520 ± 0.0005 inch)
8K-7398	Ø 114.376 ± 0.020 mm (4.5030 ± 0.0008 inch)	Ø 133.426 ± 0.020 mm (5.2530 ± 0.0008 inch)
8K-9585	Ø 114.376 ± 0.013 mm (4.5030 ± 0.0005 inch)	Ø 114.376 ± 0.013 mm (4.5030 ± 0.0005 inch)
8R-4769	Ø 127.076 ± 0.015 mm (5.0030 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
8R-6188	Ø 209.687 ± 0.015 mm (8.2554 ± 0.0006 inch)	Ø 174.762 ± 0.015 mm (6.8804 ± 0.0006 inch)
8R-6619	—	Ø 75.051 ± 0.015 mm (2.9548 ± 0.0006 inch)
8R-8141	Ø 114.385 ± 0.015 mm (4.5033 ± 0.0006 inch)	Ø 90.054 ± 0.015 mm (3.5454 ± 0.0006 inch)
8R-8142	Ø 96.913 ± 0.015 mm (3.8155 ± 0.0006 inch)	Ø 85.800 ± 0.015 mm (3.3780 ± 0.0006 inch)
8R-8142 159-7446	Ø 85.800 ± 0.015 mm (3.3779 ± 0.0006 inch)	Ø 96.913 ± 0.015 mm (3.8155 ± 0.0006 inch)
8R-8336 108-2836 127-9096 148-9288	Ø 114.385 ± 0.015 mm (4.5033 ± 0.0006 inch)	Ø 90.054 ± 0.015 mm (3.5454 ± 0.0006 inch)
8R-8503	—	Ø 75.038 ± 0.015 mm (2.9543 ± 0.0006 inch)
8R-9281	Ø 88.977 mm (3.5030 inch)	Ø 85.057 mm (3.3487 inch)
8R-9440	Ø 88.977 ± 0.015 mm (3.5030 ± 0.0006 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
8R-9737	Ø 88.977 mm (3.5030 inch)	Ø 85.057 mm (3.3487 inch)
8S-6995	Ø 127.076 ± 0.015 mm (5.0030 ± 0.0006 inch)	Ø 110.038 ± 0.013 mm (4.3322 ± 0.0005 inch)
8W-5112	Ø 80.037 ± 0.015 mm (3.1511 ± 0.0006 inch)	Ø 65.038 ± 0.015 mm (2.5606 ± 0.0006 inch)
8W-5587 582-8979	Ø 70.038 ± 0.015 mm (2.7574 ± 0.0006 inch)	Ø 65.038 ± 0.015 mm (2.5606 ± 0.0006 inch)
8W-6756	Ø 114.376 ± 0.021 mm (4.5029 ± 0.0008 inch)	Ø 133.426 ± 0.020 mm (5.2530 ± 0.0008 inch)
8W-6757	Ø 108.026 ± 0.02 mm (4.2530 ± 0.0008 inch)	Ø 85.800 ± 0.02 mm (3.3780 ± 0.0008 inch)
8W-8740	Ø 152.588 ± 0.02 mm (6.0074 ± 0.0008 inch)	Ø 152.512 ± 0.02 mm (6.0044 ± 0.0008 inch)
8W-9543	Ø 174.81 ± 0.02 mm (6.8823 ± 0.0008 inch)	Ø 152.588 ± 0.02 mm (6.0074 ± 0.0008 inch)
8W-9544	Ø 152.588 ± 0.02 mm (6.0074 ± 0.0008 inch)	Ø 152.512 ± 0.02 mm (6.0044 ± 0.0008 inch)
8X-0244	Ø 174.81 ± 0.02 mm (6.8823 ± 0.0008 inch)	Ø 152.588 ± 0.02 mm (6.0074 ± 0.0008 inch)
9C-8156	—	Ø 75.051 ± 0.015 mm (2.9548 ± 0.0006 inch)
9C-8161 143-9513	—	Ø 75.040 ± 0.015 mm (2.9543 ± 0.0006 inch)
9C-9771	Ø 90.056 ± 0.015 mm (3.5455 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
9K-1394	Ø 77.8383 ± 0.013 mm (3.0645 ± 0.0005 inch)	—
9K-2939	Ø 114.375 ± 0.015 mm (4.5030 ± 0.0006 inch)	Ø 117.550 ± 0.015 mm (4.6280 ± 0.0006 inch)
9K-5650	Ø 82.601 ± 0.013 mm (3.252 ± 0.0005 inch)	Ø 82.601 ± 0.013 mm (3.2520 ± 0.0005 inch)
9U-0113	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 117.565 ± 0.015 mm (4.6290 ± 0.0006 inch)
9U-0471	Ø 110.060 ± 0.015 mm (4.3331 ± 0.0006 inch)	Ø 110.060 ± 0.015 mm (4.3331 ± 0.0006 inch)
9V-5725	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
9V-4330	Ø 75.050 ± 0.015 mm (2.9547 ± 0.0006 inch)	Ø 75.050 ± 0.015 mm (2.9547 ± 0.0006 inch)
100-4504	Ø 127.076 ± 0.015 mm (5.0030 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
101-7513	Ø 114.437 ± 0.021 mm (4.5053 ± 0.0008 inch)	Ø 133.469 ± 0.02 mm (5.2547 ± 0.0008 inch)
102-7507 142-0444	Ø 114.39 mm (4.5033 inch)	Ø 90.05 mm (3.5454 inch)
102-7519	Ø 114.39 ± 0.05 mm (4.5035 ± 0.0019 inch)	Ø 90.05 ± 0.05 mm (3.5453 ± 0.0019 inch)
103-2010 206-9670	—	Ø 75.040 mm (2.9543 inch)
104-3359	Ø 85.057 ± 0.05 mm (3.3487 ± 0.0019 inch)	Ø 88.977 ± 0.05 mm (3.5030 ± 0.0019 inch)
104-4698 124-6022	Ø 174.81 ± 0.02 mm (6.8823 ± 0.0008 inch)	Ø 152.588 ± 0.02 mm (6.0074 ± 0.0008 inch)
104-6738	Ø 85.057 ± 0.05 mm (3.3487 ± 0.0019 inch)	Ø 88.977 ± 0.05 mm (3.5030 ± 0.0019 inch)
104-6746	Ø 96.913 mm (3.8155 inch)	Ø 85.800 mm (3.3780 inch)
105-2073 129-6659 149-0191	Ø 90.056 ± 0.015 mm (3.5455 ± 0.0006 inch)	Ø 85.050 ± 0.015 mm (3.3484 ± 0.0006 inch)
105-4026	Ø 110.060 mm (4.3331 inch)	Ø 110.060 mm (4.3331 inch)
105-8720 208-7534	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 110.06 ± 0.015 mm (4.3331 ± 0.0006 inch)
106-6580	Ø 90.056 ± 0.015 mm (3.5455 ± 0.0006 inch)	Ø 82.625 ± 0.015 mm (3.2530 ± 0.0006 inch)
107-7857	Ø 114.437 ± 0.021 mm (4.5053 ± 0.0008 inch)	Ø 132.842 ± 0.020 mm (5.230 ± 0.0008 inch)
109-4717	—	Ø 75.051 ± 0.015 mm (2.9548 ± 0.0006 inch)
112-7521 159-5963	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 110.06 ± 0.015 mm (4.3331 ± 0.0006 inch)
112-7524	Ø 120.745 ± 0.05 mm (4.7537 ± 0.0019 inch)	Ø 110.06 ± 0.05 mm (4.3331 ± 0.0019 inch)
116-8235 154-6622	Ø 139.837 ± 0.020 mm (5.5054 ± 0.0008 inch)	Ø 133.469 ± 0.015 mm (5.2547 ± 0.0006 inch)
118-5025	—	Ø 75.051 ± 0.015 mm (2.9548 ± 0.0006 inch)
129-4304 372-4769	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 110.06 ± 0.015 mm (4.3331 ± 0.0006 inch)
130-1848	Ø 120.74 ± 0.05 mm (4.7537 ± 0.0019 inch)	Ø 110.06 ± 0.05 mm (4.3331 ± 0.0019 inch)
135-7496	Ø 120.74 ± 0.05 mm (4.7537 ± 0.0019 inch)	Ø 110.06 ± 0.05 mm (4.3331 ± 0.0019 inch)
136-6550	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)	Ø 88.977 ± 0.015 mm (3.5030 ± 0.0006 inch)
137-8859	Ø 139.8 ± 0.015 mm (5.5039 ± 0.0006 inch)	Ø 114.4 ± 0.015 mm (4.5039 ± 0.0006 inch)
138-1612	—	Ø 75.040 ± 0.015 mm (2.9543 ± 0.0006 inch)
141-3124	Ø 241.450 ± 0.025 mm (9.5057 ± 0.001 inch)	Ø 489.468 ± 0.025 mm (19.2704 ± 0.001 inch)
144-4464	Ø 88.977 mm (3.5030 inch)	Ø 85.057 mm (3.3487 inch)
144-4465 372-4788	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)	Ø 88.977 ± 0.015 mm (3.5030 ± 0.0006 inch)
154-2688	Ø 80.037 ± 0.015 mm (3.1511 ± 0.0006 inch)	Ø 65.038 ± 0.015 mm (2.5606 ± 0.0006 inch)
171-4736 173-5349	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
171-6760	Ø 95.038 ± 0.015 mm (3.7417 ± 0.0006 inch)	Ø 95.038 ± 0.015 mm (3.7417 ± 0.0006 inch)
171-6763	Ø 95.038 ± 0.015 mm (3.7417 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
191-3576	—	Ø 75.051 ± 0.015 mm (2.9548 ± 0.0006 inch)
203-2289	Ø 174.70 ± 0.02 mm (6.8779 ± 0.0008 inch)	Ø 150.056 ± 0.013 mm (5.9077 ± 0.0005 inch)
211-0095	Ø 50.00 mm (1.9685 inch)	Ø 50.00 mm (1.9685 inch)
218-0766	—	Ø 75.051 mm (2.9548 inch)
237-9201	—	Ø 75.051 mm (2.9548 inch)
237-9202	—	Ø 75.051 ± 0.015 mm (2.9548 ± 0.0006 inch)
242-8686	Ø 139.81 ± 0.015 mm (5.5043 ± 0.0006 inch)	Ø 114.4 ± 0.015 mm (4.5039 ± 0.0006 inch)
252-7945	Ø 85.80 ± 0.015 mm (3.3780 ± 0.0006 inch)	—
256-1109	Ø 85.80 ± 0.015 mm (3.3780 ± 0.0006 inch)	—
256-3746	Ø 85.80 ± 0.015 mm (3.3780 ± 0.0006 inch)	—
258-2398	Ø 85.80 ± 0.015 mm (3.3780 ± 0.0006 inch)	—
265-9508	Ø 85.80 ± 0.015 mm (3.3780 ± 0.0006 inch)	—
265-9509	Ø 85.80 ± 0.015 mm (3.3780 ± 0.0006 inch)	—
271-1674 289-8601	Ø 88.975 ± 0.015 mm (3.5030 ± 0.0006 inch)	Ø 75.045 ± 0.015 mm (2.9545 ± 0.0006 inch)
273-9001	Ø 139.837 ± 0.015 mm (5.5053 ± 0.0006 inch)	Ø 130.125 ± 0.015 mm (5.1230 ± 0.0006 inch)
279-5128	Ø 241.450 ± 0.025 mm (9.50569 ± 0.001 inch)	Ø 489.468 ± 0.025 mm (19.2704 ± 0.001 inch)
282-1775 368-9128 466-3321	Ø 174.70 ± 0.02 mm (6.8779 ± 0.0008 inch)	Ø 150.056 ± 0.013 mm (5.9077 ± 0.0005 inch)
287-8222	Ø 88.975 ± 0.015 mm (3.503 ± 0.0006 inch)	Ø 85.045 ± 0.015 mm (3.3482 ± 0.0006 inch)
287-8261	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 105.05 ± 0.015 mm (4.1358 ± 0.0006 inch)
287-8228	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 95.05 ± 0.015 mm (3.7421 ± 0.0006 inch)
289-8600	Ø 88.975 ± 0.015 mm (3.5030 ± 0.0006 inch)	Ø 75.045 ± 0.015 mm (2.9545 ± 0.0006 inch)
308-3247	Ø 139.857 ± 0.020 mm (5.5062 ± 0.0008 inch)	—
323-4150	Ø 95.038 ± 0.015 mm (3.7417 ± 0.0006 inch)	Ø 95.038 ± 0.015 mm (3.7417 ± 0.0006 inch)
323-4151	Ø 95.038 ± 0.015 mm (3.7417 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
326-0535 508-8369	Ø 88.977 ± 0.015 mm (3.5030 ± 0.0006 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
333-4622	Ø 95.038 ± 0.015 mm (3.7417 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
333-4623	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)
344-6003	Ø 139.857 ± 0.020 mm (5.5062 ± 0.0008 inch)	—
355-1143	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
355-1154	Ø 114.385 ± 0.015 mm (4.5033 ± 0.0006 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
361-7764	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 90.055 ± 0.015 mm (3.5455 ± 0.0006 inch)
361-7768	Ø 110.065 ± 0.015 mm (4.3333 ± 0.0006 inch)	Ø 90.055 ± 0.015 mm (3.5455 ± 0.0006 inch)
365-1300	Ø 80.00 mm (3.1496 inch)	Ø 80.00 mm (3.1496 inch)
365-1301	Ø 80.00 mm (3.1496 inch)	Ø 80.00 mm (3.1496 inch)
365-1302	Ø 105.0 mm (4.1339 inch)	Ø 80.00 mm (3.1496 inch)
365-1781 556-4474	Ø 110.038 ± 0.015 mm (4.3322 ± 0.0006 inch)	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)
367-2024	Ø 139.81 ± 0.015 mm (5.5043 ± 0.0006 inch)	Ø 114.4 ± 0.015 mm (4.5039 ± 0.0006 inch)
376-0135	Ø 70.038 ± 0.015 mm (2.7574 ± 0.0006 inch)	Ø 65.038 ± 0.015 mm (2.5606 ± 0.0006 inch)
376-3744	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 114.4 ± 0.015 mm (4.5039 ± 0.0006 inch)
386-0310	120.745 ± 0.05 mm (4.75373 ± 0.0019 inch)	Ø 110.06 ± 0.05 mm (4.3331 ± 0.0019 inch)
386-0311	Ø 120.745 ± 0.05 mm (4.7537 ± 0.0019 inch)	Ø 114.4 ± 0.05 mm (4.5039 ± 0.0019 inch)
385-1794	Ø 88.977 ± 0.015 mm (3.5030 ± 0.0006 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
387-4570	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 110.06 ± 0.015 mm (4.3331 ± 0.0006 inch)
416-4654	Ø 152.505 ± 0.015 mm (6.0041 ± 0.0006 inch)	Ø 139.81 ± 0.015 mm (5.5043 ± 0.0006 inch)
434-1446	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 90.055 ± 0.015 mm (3.546 ± 0.0006 inch)
436-6569	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
442-1499	Ø 45.0 mm (1.772 inch)	Ø 45.0 mm (1.772 inch)
442-1918	Ø 139.837 ± 0.015 mm (5.5054 ± 0.0006 inch)	Ø 130.125 ± 0.015 mm (5.1230 ± 0.0006 inch)
442-3959 559-1901	Ø 45.0 mm (1.772 inch)	Ø 45.0 mm (1.772 inch)
449-2992	Ø 120.745 ± 0.015 mm (4.7537 ± 0.0006 inch)	Ø 114.40 ± 0.015 mm (4.504 ± 0.0006 inch)
544-0641	Ø 88.977 ± 0.015 mm (3.5030 ± 0.0006 inch)	Ø 85.057 ± 0.015 mm (3.3487 ± 0.0006 inch)
544-0642	Ø 79.27 ± 0.05 mm (3.1209 ± 0.0019 inch)	Ø 79.27 ± 0.05 mm (3.1209 ± 0.0019 inch)

(1)	The most current part number is identified in the bold font when multiple part numbers are in a cell.

Part Description

Table 5

Base Metal	Ductile Iron
Hardness	Wheel Loader, Wheel Tractor Scraper, Wheel Dozer, and 797: 28 - 34 Rc 69D - 793D and Articulated Truck: 179 - 229 BHN Integrated Toolcarrier: 156 - 217 BHN

Arc Spray Equipment and Procedure

Table 6

Arc Spray Equipment
Maximum Surface Texture	1.6 µm (63.00 µinch) 69D - 793D Only: 2.5 µm (100.00 µinch)
Reason for Spraying	Wear, grooving, or corrosion
Mating Part Contact Area & Material	Bearing
Arc Spray Equipment Type	SmartArc by Oerlikon Metco PPG Electric Arc Gun, TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA Top 30T Wire Coat, TAFA 75B Bond Coat
Finish Thickness	As Required
Spray Angle	90°
Substrate Pre-Heat Temperature	66° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Lathe or headstock/ tailstock arrangement, rotary turntable
Rotation Speed	92 SMPM (300.00 SFPM)
Surface Preparation Method	Undercut and Grit blast
Equipment Required	Milling machine or turn Lathe
Recommended Cutting Tool	ISCAR DNMG 432 TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Remarks	Before machining, assemble the cross shafts into the plain and flange halves, lubricate the bolts and torque the bolts to specification. Assembly will hold concentricity.

Table 7

Arc Spray Procedure
Arc Spray		Procedure		Check List
Clean Part		Degrease in hot caustic solution
Undercut		If desired
Chamfer		If required - 1.0 mm (0.039 inch) x 45°
Remove Oxide		Use emery cloth or glass bead blaster
Clean Spray Area		Commercial degreaser
Mask for Grit Blaster		Duct tape, metal shield, or rubber
Grit Blast Equipment		Pressure type only
Grit Type and Size		20 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask		Remove mask material, make sure that surface is clean
Mask for Metal Spray		Antibond, blue layout dye, duct tape, metal shield, or rubber
Metal Spray Equipment Type		SmartArc by Oerlikon Metco	TAFA
	Consumable (Bondcoat)	TAFA 75B	TAFA 75B
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	128 mm (5.0 inch)	128 mm (5.0 inch)
	Spray Rate/Bond Pass	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Consumable (Topcoat)	TAFA 30T	TAFA 30T
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	31V	31V
	Amps	150 Amps	175 Amps
	Gun to Work Distance (Standoff)	166 mm (6.5 inch)	166 mm (6.5 inch)
	Spray Rate/Build Up	0.058 mm (0.0023 inch)/pass	0.058 mm (0.0023 inch)/pass
	Rotation Speed of Part (RPM)	RPM varies depending on diameter
	Rotation Speed of Part	92 SMPM (300 SFPM)
	Traverse Rate of Gun	11 SMPM (40 SFPM)
Gun Fixturing Method		Machine mount or hand held
Finishing Equipment		Milling machine or Lathe
Part/Cutter Rotation Roughing		50 SMPM (150.00 SFPM)
Part/Cutter Rotation Finishing		75 SMPM (250.00 SFPM)
Coolant		Oil base synthetic - 40:1 ratio
Traverse Speed		0.30 mm (0.012 inch)
Depth of Rough Cut		0.51 mm (0.020 inch)
Depth of Finish Cut		0.25 mm (0.010 inch)

Flame Spray Equipment and Procedure

Table 8

Flame Spray Equipment
Maximum Surface Texture	Bearing - 1.6 µm (63.00 µinch) 69D - 793D Only: 2.5 µM (100.00 µinch) Ring Gear - (2.5-3.6) µm ((98.42-141.73 µinch) 1/2 Housing/Pinion Gear Bearing Inner Race - 7.6 µm -10.2 µm (300.00 -400.00 µinch)
Reason for Spraying	Wear
Mating Part Contact Area & Material	Bearing Ring Gear 1/2 Housing/Pinion Gear Bearing Inner Race -
Oerlikon Metco Equipment Type	6PII by Oerlikon Metco
Oerlikon Metco Material	Oerlikon Metco 453 or 452
Finish Thickness	As Required
Finishing Allowance	0.51 to 0.64 mm (0.020 to 0.025 inch) per side
Spray Angle	Bearing and Ring Gear - 90° 1/2 Housing/Pinion Gear Bearing Inner Race - 70°–90°
Substrate Pre-Heat Temperature	66° C (150° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	If desired
Rotation/Traverse Device	Lathe or turntable
Rotation/Traverse Speed	91.4 SMPM (300.00 SFPM)
Surface Preparation Method	Undercut and Grit Blast
Finishing Method	Machine
Machining Equipment Type	Lathe or Horizontal mill
Recommended Cutter Grade	C-2, 883 Carboloy, or equivalent
Remarks	Before machining, assemble the cross shafts into the plain and flange halves, lubricate the bolts and torque the bolts to specification. Assembly will hold concentricity.

Table 9

Flame Spray Procedure
Flame Spray Process (6P)	Procedure	Check List
Clean Part	Degrease in hot caustic solution
Undercut	To "tru-up" surface
Chamfer	Bearing Journals (If Required) 1.0 mm (0.039 inch) x 45° Ring Gear - 45°
Remove Oxide	Use fiber flap brush, Clean/strip disc
Clean Spray Area	Oerlikon Metco cleaning solvent or equivalent
Mask for Blast	Duct Tape and metal mask
Blast Equipment	Pressure type only
Grit Type and Size	24 mesh aluminum oxide
Blast Air Pressure	Bearing Journal - 690 kPa (100.0 psi) Ring Gear - 620 kPa (90.0 psi) 1/2 Housing/Pinion Gear Bearing inner race - 620 kPa (90.0 psi)
Blast Nozzle to Work Distance	51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
Mask for Spray	Oerlikon Metco Antibond or blue layout dye
Spray Equipment Type	6PII by Oerlikon Metco Hand Held Thermo Spray System
Auxiliary Cooling	If desired
Nozzle	6P-C7A-K "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure	210 kPa (30.0 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	5.5 kg (12 lb) per hour or 90 gr (3.2 oz) per min
Gun to Work Distance	230 mm (9.0 inch)
Rotation Speed of Part (RPM)	75–110 RPM, depending on diameter
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
Top Coat/Thickness	0.10 to 0.15 mm (0.004 to 0.006 inch) per pass
Finishing Equipment	Lathe or Horizontal mill
Part/Cutter Rotation	Bearing Journals - 91.4 SMPM (300.00 SFPM) Ring Gear - 5.2 to 6.3 SMPM (17.1 to 20.1 SFPM) 1/2 Housing/Pinion Gear Bearing inner race - 5.2 to 6.3 SMPM (150.00 to 180.00 SFPM)
Traverse Speed	0.05 to 0.10 mm (0.002 to 0.004 inch) per revolution
Depth of Rough Cut	0.38 to 0.51 mm (0.015 to 0.020 inch) per side
Depth of Finish Cut	0.25 to 0.38 mm (0.010 to 0.015 inch) per side
Additional Finish Method	Emery cloth for desired finish

Crack Detection Methods

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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 five major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Testing (VT), Liquid Penetrant Testing (PT), Dry / Wet Magnetic Particle Testing (MT), and Ultrasonic Testing (UT).

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 10 for advantages and disadvantages and Table 11 for standards and requirements for these NDT methods.

Table 10

Crack Detection Methods Advantages and Disadvantages
Detection Method	Advantages	Disadvantages
Visual Testing (VT)	- Least Expensive - Detects most damaging defects. - Immediate Results - Minimum part preparation	- Limited to surface-only defects. - Requires inspectors to have broad knowledge of welding and fabrication in addition to Non-Destructive Testing (NDT).
Liquid Penetrant Testing (PT)	- Inexpensive - Minimal Training - Portable - Works on nonmagnetic material.	- Least Sensitive - Detects surface cracks only. - Rough or porous surfaces interfere with test
Dry Magnetic Particle (MT)	- Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities	- Works on magnetic material only. - Less sensitive than Wet Magnetic Particle Testing (MT).
Wet Magnetic Particle (MT)	- More sensitive than Liquid Penetrant Testing (PT). - Detects subsurface as much as 0.13 mm (0.005 inch).	- Requires power for light. - Works on magnetic material only. - Liquid composition and agitation must be monitored.
Ultrasonic Testing (UT)	- Most Sensitive - Detects deep material defects. - Immediate Results - Wide range of materials and thickness can be inspected	- Most Expensive - Requires operator training and certification. - Surface must be accessible to probe

Table 11

Applicable Crack Detection Standards
Detection Method	Standard	Acceptance Criteria	Minimum Required Personnel Qualifications
Visual Testing (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A
Magnetic Particle Testing (MT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A
Ultrasonic Testing (UT)	EN-ISO 17640 - Level B AWS D1.1	EN-ISO 11666 Technique 2 - Level 2 AWS D1.1 - Class A - Table 6.3	EN-ISO 9712 ANSI-ASNT SNT-TC-1A

Visual Testing (VT)

Illustration 25	g06124166
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 Visual Testing (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration 25. 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)

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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 Table3 for 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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Illustration 26	g06084048
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.
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   Illustration 27	g06084053
   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.
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   Illustration 28	g06084060
   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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   Illustration 29	g06084070
   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.
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   Illustration 30	g03773759
   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 30. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MT)

Materials and Equipment Required

Refer to Tooling and Equipment Table3 for part numbers.

Illustration 31	g06085930
(A) Indications shown by Dry Magnetic Particle Testing (MT). (B) 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. 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

Refer to Tooling and Equipment Table3 for part numbers.

Illustration 32	g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MT). (B) Electromagnetic Yoke (D) Ultraviolet Lamp

Illustration 33	g06003178
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:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. 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 33. 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.

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

   4. 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.

   5. 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 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.
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   Illustration 34	g03536210

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. Refer to Illustration 34 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.

Ultrasonic Testing (UT)

Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can be detected by an experienced technician. Refer to Table 11 for crack detection standards.

Refer to Tooling and Equipment Table3 for part numbers.

1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.

2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.

   1. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect from the back surface of the material to project the thickness of the material.

   2. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.