Inspection and Salvage of Rear Wheel Spindles for Certain Off-Highway Trucks {4201, 4205} Caterpillar

Off-Highway Truck/Tractor

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

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

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

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

769 (S/N: 99F1-UP)

769B (S/N: 99F1-UP)

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

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

770 (S/N: BZZ1-UP)

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

772 (S/N: RLB1-UP; 11S1-UP)

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

772G (S/N: KE31-UP; RME1-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)

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: 1HW1-UP; APX1-UP; 5AZ1-UP)

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

785G (S/N: RTL1-UP)

789 (S/N: 9ZC1-UP)

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

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

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

789G (S/N: TR21-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP; 4AR1-UP)

793C (S/N: CBR1-UP; 4AR1-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)

793F AC (S/N: EMD1-UP)

794 AC (S/N: MN51-UP; MT51-UP; HRT1-UP)

795F AC (S/N: ERM1-UP)

795FAC XQ (S/N: SNT1-UP)

796 AC (S/N: HRZ1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

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

798 AC (S/N: ST71-UP)

MT4400D AC (S/N: MH41-UP; MT41-UP)

OEM POWERTRAIN (S/N: DTE1-UP)

Quarry Truck

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

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

773G (S/N: 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)

Introduction

Table 1

Revision	Summary of Changes in SEBF8083
23	Added new serial number prefixes. Updated 11. Updated part number 467-0158 for Table 3.
22	Changed title from "Inspection and Salvage of Rear Wheel Spindles for All Off-Highway Trucks" to "Inspection and Salvage of Rear Wheel Spindles for Certain Off-Highway Trucks". Updated effectivity. Added the web address of the manufacturer for the carbon fiber snap gages in Table 3. Revised Illustrations 3, 9, 10, 11, 25, 28, 32, 33, 34, 49, 58, ,59, 72, 79, and 91. Revised the section and updated the boilerplate information.
21	Revised tables added carbon fiber snap gages and updated clarity of crack repair. Inserted contents from SEBF2167Reuse And Salvage Guideline, "Thermal Spray Procedures for OHT Rear Spindles" into this media. Updated the boilerplate information.
20	Updated dimensions and added 497-3506.
19	Updated and corrected dimensions in Table 11.
18	Updated confidentiality statement and improved illustrations.

© 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

This guideline provides the procedures that are necessary to determine the reusability of rear spindles for certain Off-Highway Trucks. Life will vary depending on application, load, lubrication, and environment.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part meets the specifications within this guideline and the part is intended for a similar application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to condemn a part from reuse. Follow visual inspections and the "Crack Detection Methods" section for further guidance.

References

Table 2

References
Media Number	Publication Type & Title
Channel1	"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"
SEBD0512	Reuse and Salvage Guidelines "AVSpare Service Welding Guide"
SEBF8187	Reuse and Salvage Guidelines "Standardized Parts Marking Procedures"
SEBF8728	Reuse and Salvage Guidelines "Specifications for Inspection of Driveline Fasteners"
SEBF9236	Reuse and Salvage Guidelines "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for reconditioning Components" (1)
SEBF9238	Reuse and Salvage Guidelines "Fundamentals of Arc Spray for reconditioning Components" (1)
SEHS8792	Special Instruction "Using AVSpare Replacement Thread Inserts"

(1)	Only Cat dealers may utilize applications for Thermal Spray. The processes must be carried out within the facilities of the dealership. The dealership must maintain a clean environment and always use the correct equipment for all processes in each Thermal Spray Application.

Service Advisories, Service Letters, and Technical Service Bulletins

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

Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

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
8H-8581	Feeler Gauge 0.038 - 0.635 mm (0.0015 - 0.0250 inch)	Thickness Measurement Checks
5P-3920	Tool Rule 304.8 mm (12.00 inch)	Measurement Checks
90141 (3)	Instrument Group Carbon Fiber Snap Gages Gage to Check 425.415 ± 0.025 mm (16.7486 ± 0.0010 inch)	External Measurement Checks
92268-2 (3)	Instrument Group Carbon Fiber Snap Gages Gage to Check 288.895 ± 0.025 mm (11.3738 ± 0.0010 inch)	External Measurement Checks
92270-2 (3)	Instrument Group Carbon Fiber Snap Gages Gage to Check 234.92 ± 0.025 mm (9.249 ± 0.0010 inch)	External Measurement Checks
92531-2 (3)	Instrument Group Carbon Fiber Snap Gages Gage to Check 317.457 ± 0.025 mm (12.4983 ± 0.0010 inch)	External Measurement Checks
92718-2 (3)	Instrument Group Carbon Fiber Snap Gages Gage to Check 346.032 ± 0.025 mm (13.6233 ± 0.0010 inch)	External Measurement Checks
385-8484	Tool (Level) 305 mm (12 inch)	Level
— 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
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-8515	Grinding Wheel (F-Grade) (2 x 1 inch) (120 Grit)	Surface Preparation / De-burring
6V-2010	Polishing Stone	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
9U-7377 (4)	Metal Marking Pen	Parts Marking
6V-6035	Hardness Tester	Hardness Check
—	GE MIC 10 Hardness Tester	Hardness Check
8T-5096	Tool Group Dial Indicator	Run-Out Checks
9S-8903	Indicator Contact Point	Run-Out Checks
5P-7414	Seal Pick Kit	Gear/ Shaft Step Inspection
262-8390	Microscope (40-Power) Pocket	Crack/ Measurement Inspection
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
453-5376	Tool Specimen	Surface Texture Tester
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
549-3505 (5)	Pin Set 4.0 mm	Measurement Over Pin / MOP Spline Wear Inspection
—	Precision Gage Pins (6) Ø 4.7625 mm (0.18750 inch) x 50.8 mm (2.00 inch)	Measurement Over Pin / MOP Spline Wear Inspection
—	Precision Gage Pins (6) Ø 4.877 mm (0.1920 inch) x 50.8 mm (2.00 inch)	Measurement Over Pin / MOP Spline Wear Inspection
—	Precision Gage Pins (6) Ø 6.3500 mm (0.25000 inch) x 50.8 mm (2.00 inch)	Measurement Over Pin / MOP Spline Wear Inspection
—	Precision Gage Pins (6) Ø 7.9375 mm (0.31250 inch) x 50.8 mm (2.00 inch)	Measurement Over Pin / MOP Spline Wear Inspection
549-3510 (5)	Pin Set 8.0 mm	Measurement Over Pin / MOP Spline Wear Inspection
549-3520 (5)	Tool (Magnet) (7)	Gage Pin Magnetizer/ Demagnetizer
—	Large Rubber Band	MOP Small Gear/ Spline Wear Inspection
—	Bungee Cord	MOP Large Gear/ Spline Wear Inspection
—	Temperature Indicating Crayon	Welding Pre-Heat
154-9316	File Metric	Threaded Shaft / Restore
— or —	Carbon Arc Gouging Torch	Weld Removal/ Crack Excavation
	Plasma Arc Gouging Torch	Weld Removal/ Crack Excavation
4C-8514	Wheel (2 x 1 inch) (60 Grit)	Surface Preparation / De-burring
349-4202	Thermometer Infrared -12:1 Ratio	Temperature Checks
4C-4160	Tool Tip 101,200 - 202,404 BTU/hr	Welding Pre-Heat
4C-4161	Tip 139,150 - 328,900 BTU/hr	Welding Pre-Heat
4C-4162	Tip 215,050 - 581,900 BTU/hr	Welding Pre-Heat
4C-4163	Tip 404,800 - 822,250 BTU/hr	Welding Pre-Heat
4C-4164	Tip 455,400 - 1,012,000 BTU/hr	Welding Pre-Heat
4C-5823	Handle Torch	Welding Pre-Heat
4C-5830	Tool Mixer Oxy-Propane	Welding Pre-Heat
4C-9618	Welding Blanket	Post Welding Treatment
222-3080	Air Hammer	Weld Removal
223-4356	Breaker Assembly	Weld Removal
222-3071	Portable Angle Grinder Group	Welding Preparation Weld Removal/ Crack Excavation
222-3074	Wheel Grinder Group	Welding Preparation Weld Removal/ Crack Excavation
222-3076	Die Grinder (Right Angle)	Surface Preparation / De-burring
236-8097	Carbide Burr	Welding Preparation Weld Removal/ Crack Excavation
254-5319	Brush 76.2 x 50.8 mm (3.00 x 2.00 inch)	Surface Preparation / De-burring
4C-4113	Tool Group (Oxy-Propane)	Welding Preparation Crack Excavation
4C-3770	Grinding Wheel	Welding Surface Preparation/ Finish
4C-9616	Blanket Welding	Post Welding Treatment
—	Welding, Cutting, and Gouging Equipment	General Welding
—	Weld Size Inspection Gauges	Post Weld Inspection
—	Arc Spray System	Thermal Spray
—	HVOF Spray System	Thermal Spray
—	Suitable Lathe	Machining
9A-1593	Comparison Gauge (Surface Texture)	Surface Texture Tester
448-3698	Indicator (Profilometer)	Surface Texture Tester
479-5400 (8)	Paint Yellow	Touch Up
458-9587 (9)	Paint Yellow	Touch Up
—	Reflective Surface for Inspection	Visual Testing (VT)
— (2)	Bright Incandescent Light	Visual Testing (VT)
1U-9367	Automatic Tape Measure (1-inch X 26- ft) 25.4- mm x 8- m	Visual Testing (VT)
8S-2257	Magnifying Glass	Visual Testing (VT)
9U-6182	Mirror (Telescoping)	Visual Testing (VT)
9U-7231	Flashing Lights Conversion Kit	Visual Testing (VT)
4C-9442	Light	Visual Testing (VT)
1U-9915	Brush Curved Handle Wire	General Cleaning/ Liquid Penetrant Testing (PT)
—	Developer	Liquid Penetrant Testing (PT)
—	Penetrating Oil	Liquid Penetrant Testing (PT)
288-4209	Paper Towel	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)

(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)	Dorsey Metrology International web address: https://www.dorseymetrology.com/
(4)	Available in the United States only.
(5)	Part of Tool Group 549-3500.
(6)	Minimum of two are required.
(7)	For use with precision gage pins.
(8)	Available in Canada, APD, and EAME.
(9)	Available in North and South America (except Canada).

Preparation Recommendations

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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	g06430973
Typical example of spindle after cleaning.

Note: Clean exterior of the spindle prior to disassembly to minimize cross-contamination.

• Before you inspect the spindle, clean the spindle thoroughly to ensure it is 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 spindle.

• During cleaning, do not damage machined surfaces.

• 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 for fretting. 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.

1. Perform a thorough visual inspection for defects and damage.
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   Illustration 4	g03794147
   Typical burr removal Tooling. (A) Die Grinder, Right Angle (B) Wheel Grinder, Group (C) Conditioning Discs, Disc pad Holder, and Threaded Shaft (D) Flapper Wheel

2. Inspect all flange mating surfaces and sealing surfaces. Ensuring that all flange mating surfaces and sealing surfaces are true and free from raised material resulting from rust, nicks, burrs, and dents.
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   Illustration 5	g06139437
   (G) Typical example of chasing threaded holes.

3. Remove any broken bolts, use appropriate thread taps to chase all threaded holes.
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   Illustration 6	g06139440
   Typical example of checking threaded holes using GO/NO-GO thread gauges. (H) NO-GO Thread Gauge (J) GO Thread Gauge

4. Inspect all threaded holes with appropriate GO/NO-GO thread gauges.

   Note: NO-GO thread gauge (H) can be screwed into threaded hole no more than two turns. For acceptance of part, GO thread gauge (J) should pass through the entire length of the threaded hole without requiring too much rotational force.

   1. If NO-GO thread gauge (H) exceeds two turns, then repair threads.

Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

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.

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 7	g03748255
Typical Example

Illustration 7 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.

Example 2

Illustration 8	g03748362
Typical Example

Illustration 8 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 10,000 hours accumulated on the component between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the component in Illustration 8. In this example, the component has a total of 22,000 hours.

Identification of Spindle Type

Illustration 9	g06431017
Type 1 is a two-piece rear spindle. This spindle is used by certain 772, 773, and 775 Off-Highway Truck models.

Illustration 10	g06479393
Type 2 rear spindle that is used by all other Off-Highway Trucks.

Illustrations 9 and 10, show a typical configuration for a rear wheel spindle. Use the Illustrations 9 and 10 to determine the type of spindle.

Inspection

To protect the operator, always wear Personal Protective Equipment (PPE) for the operator's protection.

Always use suitable rigging practices and lifting devices for the safety of the operator and to prevent damage to the components.

The spindles and splines must be inspected prior to any repair. These splines are subject to high loads. This makes accurate inspection essential. Splines should be inspected immediately after removal. If the splines are not immediately inspected, hydraulic oil should be applied to each machined surface to prevent rust or corrosion.

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NOTICE
DO NOT install cracked spindles that are deemed not repairable within this guideline.

Entire Spindle - Inspect the spindle for cracks. Use either liquid penetrant testing or magnetic particle testing during the inspection process. An internal crack can lead to a failure after a salvage procedure.

• Spindles that can be salvaged refer to Table 14.

• Spindles that cannot be salvaged refer to Table 15.

• Crack length acceptabilities refer to Table 16.

• Welding repair parameters refer to Table 24.

To prevent a failure, inspect each of the following critical areas of a spindle:

• 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 or the average dimension between pins to determine wear. If spline on spindle is cracked, then DO NOT USE PART AGAIN.

• Bearing Journals - Measure the surface hardness and the outside diameter for each journal. Bearing journals may be salvaged by using Arc Spray or 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.

Wheel Bearing Journals

Illustration 11	g06479376
Typical example of bearing journals

Bearing journals 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. Check each component for cracks, bruising, scratching, or spalling. It can also be difficult to distinguish between small scratches and small cracks. In these cases, perform Liquid Penetrant Testing (PT) or Magnetic Particle Testing (MT), refer to the "Crack Detection Methods" section.

If any defects are present, DO NOT USE PART until the component is salvaged. The component can be used after performing the applicable salvage procedure.

Normal Wear

Illustrations 12 through 15 show both inner and outer wheel bearing journal.

Note: The reusability criteria are the same for both inner and outer bearing journals.

Illustration 12	g03680466
The outer bearing journal surface has been laser hardened. Shiny area (A) has been buffed slightly to check the hardness, OK TO USE PART AGAIN. (A) Shiny Area

Illustration 13	g03680470
Illustration 13 shows a laser hardened inner bearing journal that exhibits normal wear. Once the corrosion has been removed from the surface, then OK TO USE PART AGAIN.

Illustration 14	g03680472
Illustration 14 shows an inner bearing journal that exhibits normal wear, OK TO USE PART AGAIN.

Illustration 15	g06430911
Illustration 15 shows an inner bearing journal that exhibiting light wear (B) and light pitting (C), OK TO USE PART AGAIN. (B) Light Wear (C) Light Pitting

Surface Damage

To recondition the surface of a bearing journal, refer to the "Thermal Spray Procedures for OHT Rear Spindles" section for further information.

Illustration 16	g06430884
Illustration 16 shows a bearing journal surface that exhibits smearing damage (D). Before reusing the spindle, buff the surface and verify the dimensions. Refer to Tables 10 and 11. OK TO USE PART AGAIN (D) Smearing Damage

Illustration 17	g06430929
Illustration 17 shows an outer journal that exhibits bruising (E). A band of corrosion (F) is shown below the journal. DO NOT USE PART AGAIN Bearing journal may be salvaged using "Thermal Spray Procedures for OHT Rear Spindles". (E) Bruising (F) Band of Corrosion

Note: If band of corrosion (F) is the only damage, then the spindle may be reused after you buff the corrosive area.

Illustration 18	g03680490
Illustration 18 shows an outer bearing journal exhibits scratching and spalling damage, DO NOT USE PART AGAIN. Bearing journal may be salvaged using "Thermal Spray Procedures for OHT Rear Spindles".

Illustration 19	g03680493
Typical example of an outer bearing journal that exhibits heavy damage from spalling, DO NOT USE PART AGAIN. Bearing journal may be salvaged using ."Thermal Spray Procedures for OHT Rear Spindles".

Illustration 20	g03680502
Typical example of an outer bearing journal with a layer of thermal spray material missing, DO NOT USE PART AGAIN. Bearing journal may be salvaged using ."Thermal Spray Procedures for OHT Rear Spindles".

Illustration 21	g03680509
Typical example of an inner bearing journal that exhibits scratching and spalling damage, DO NOT USE PART AGAIN. Bearing journal may be salvaged using ."Thermal Spray Procedures for OHT Rear Spindles".

Illustration 22	g03680513
Typical example of an inner bearing journal with a layer of thermal spray material that has started to flake off. The bond between the bearing journal and the thermal spray material failed, DO NOT USE PART AGAIN. Bearing journal may be salvaged using "Thermal Spray Procedures for OHT Rear Spindles".

Illustration 23	g06430861
Illustration 23 shows a scalloped edge on the wheel that has caused the inner bearing journal to wear a rounded groove into the spindle, OK TO USE PART AGAIN. The depth of the groove must not exceed 2.000 mm (0.0787 inch). Buff the surface to eliminate sharp edges or grooves.

Brake Anchor Flange

Illustration 24	g06430848
Typical example of a spindle that has cracked at the radius near the brake anchor flange, DO NOT USE PART AGAIN.

Porosity of Spindles

Illustration 25	g06482108
(1) Lubrication Hole (A) Automatic Electronic Traction Aid (AETA) Hole (C) Flange

Criteria for inspection have been written to help in determining the acceptability of parts by using visual inspection.

Note: The neutral axis is the axis that runs through Automatic Electronic Traction Aid (AETA) Hole (A) (where present) and lubrication hole (1) (where present). Refer to Illustration 25 for the locations of these holes.

Areas of Inspection

Illustration 26	g06430812
Top view of typical wheel spindle that is separated into four quadrants for inspection. (1) Lubrication Hole (2) Neutral Axis (3) Angle (45°)

The spindles are divided into four quadrants consisting of nine inspection areas. Refer to Illustrations 26 through 34.

Illustration 27	g06430823
Length (X) is slightly longer than the thickness of retainer (Y) that sets the location of inner bearing (AA). Refer to Table 4 for parameters of applicable sales models. (C) Flange (X) Length (Y) Retainer (Z) Seal (AA) Inner Bearing

Illustration 28	g06479324
Typical example of porous indications.

Cast Surface

The cast surface shall be free from scale, cracks, hot tears, and any sand that is adhering to the surface.

Area (4)

Illustration 29	g06491316
( 1) Lubrication Hole (4) Area (C) Flange (X) Length (Table 4)

Area (4) is the location of where the retaining seal seats on the spindle with Length (X).

• No visible defects are allowed in Area (4).

Table 4

Parameters for Acceptable Porosity
Sales Model	Length (X)(1)
777	40 mm (1.6 inch)
785 785B 785C	68 mm (2.7 inch)
789 789B 789C	68 mm (2.7 inch)
793 793B 793C 793D 793F	68 mm (2.7 inch)
797 797B 797F	68 mm (2.7 inch)

(1)	Length (X) is measured from the flange face.

Area (5)

Illustration 30	g03680722
( 1) Lubrication Hole (5) Area

Area (5) is the area around the entire circumference of the outer bearing journal.

• No more than one 3.0 mm (0.12 inch) indication (diameter and depth) is allowed in a 2500 mm ² (3.9 inch ²).

• No more than two 3.0 mm (0.12 inch) indications allowed in Area (5).

• No more than 15 total indications are allowed in Area (5).

Area (6)

Illustration 31	g03680726
( 1) Lubrication Hole (6) Area (X) Length (Table 4)

Area (6) is the area on side quadrants of the spindle but excluding the inner bearing journal and the outer bearing journal. Area (6) extends from Length (X) to the end of the spindle.

• No more than one 1.5 mm (0.06 inch) indication (diameter and depth) is allowed in a 2500 mm ² (3.9 inch ²) Area (6).

• No more than four 1.5 mm (0.06 inch) indications are allowed in Area (6).

Area (7)

Illustration 32	g06479347
( 1) Lubrication Hole (2) Neutral Axis (7) Area (X) Length (Table 4)

Area (7) is the area around Neutral Axis (2), or the area on both the top and bottom quadrants of the spindle but excluding the inner bearing journal and the outer bearing journal. Area (7) extends from Length (X) to the end of the spindle.

• No more than one 3.0 mm (0.12 inch) indication (diameter and depth) is allowed in a 2500 mm ² (3.9 inch ²) Area (7).

• No more than four 3.0 mm (0.12 inch) indications are allowed in Area (7).

Area (8)

Illustration 33	g06479364
( 1) Lubrication Hole (8) Area

Area (8) is the area on both side quadrants of the inner bearing journal.

• No more than one 1.5 mm (0.06 inch) indication (diameter and depth) is allowed in a 2500 mm ² (3.9 inch ²) Area (8).

• No more than three 1.5 mm (0.06 inch) indications are allowed in Area (8).

• No more than ten total indications are allowed in Area (8).

Area (9)

Illustration 34	g06479402
( 1) Lubrication Hole (9) Area

Area (9) is the area on both top and bottom quadrants of the inner bearing journal.

• No more than one 3.0 mm (0.12 inch) indication (diameter and depth) is allowed in a 2500 mm ² (3.9 inch ²) area.

• No more than two 3.0 mm (0.12 inch) indications are allowed in Area (9).

• No more than ten total indications are allowed in Area (9).

Splines

Splines can be visually inspected. To ensure the best results, a magnifying glass and a strong light source such as sunlight are recommended. It can also be difficult to distinguish between small scratches and small cracks. If unable to determine scratches from hair line cracks, then perform Liquid Penetrant Testing (PT) or Magnetic Particle Testing (MT).

Ensure to inspect all spline. If damaged spline is found, all spline that mate to it and all splines that are 180° from the damaged spline should be reinspected for possible fatigue from bending. Refer to "Crack Detection Methods" section for Non-Destructive Testing (NDT) procedures.

If spline is damage from misalignment, then DO NOT USE PART AGAIN. Abnormal wear will not permit full tooth contact thus result in high contact pressures.

Signs of Potential Failure

The key element to analyzing damage on final drive splines is determining if the damage will progress to a failure before the next Planned Component Rebuild (PCR). The application and size of splines are important in determining if the damage will progress.

There are two typical signs of failure:

• Spline wear or fracture from misalignment

• Cracking from fatigue which could lead to fracture

Spline Wear and Misalignment

Spline wear is the result of relative motion between mating spline teeth. High loading, insufficient lubrication, vibration, and abrasive materials may result in wear. Typically, splines can be reused if less than a 0.203 mm (0.0080 inch) wear step exists. When spline wear is excessive, movement of the joint increases causing misalignment and an imbalance which increases the rate of the deterioration of the spline. Excess clearance between splines will also create shock loading during speed, load, and/or direction changes.

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 hub and the spindle 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.

• Bearings

• Carrier Bores

• Thrust Faces of Carrier

• Carrier Shafts

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.

Normal Wear

Illustration 35	g01240365
The spline has an external wear step, but the spline meets specifications for reusability. Corrosion from fretting is also apparent. This corrosion is due to lack of lubrication, OK TO USE THIS PART AGAIN.

Illustration 36	g03680790
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, then OK TO USE THIS PART AGAIN

Wear Steps

Illustration 37	g06122435
Typical example of an external spline with no significant wear (J) steps. (J) Wear

If spline has no significant wear (J) steps, then OK TO USE PART AGAIN.

Illustration 38	g06122438
Typical example of an external spline with significant wear (K) steps, DO NOT USE PART AGAIN. (K) Wear

If wear steps are found on either external or internal splines, drag a seal pick across the step. If the wear step stops the pick, then DO NOT USE PART AGAIN.

Illustration 39	g06319105
Check the ends of location of the engagement of the splines.

If wear steps are found on either external or internal splines, drag a seal pick across the step. If the wear step stops the pick and measures more than 0.203 mm (0.0080 inch), then DO NOT USE PART AGAIN.

Remember to check the ends of the location of the engagement of the splines. If splines are not worn evenly, DO NOT USE THE PART AGAIN. Check mating spline for alignment.

Corrosion and Pitting

Illustration 40	g06324680
Typical example of corrosion from poor storage techniques, clean inspect for pitting. If excessive pitting, then DO NOT USE THIS PART AGAIN.

Illustration 41	g03680797
typical example of a spline showing heavy pitting, DO NOT USE THIS PART AGAIN.

Illustration 42	g03680798
Typical example of a spline exhibiting heavy fretting corrosion, DO NOT USE THIS PART AGAIN.

Damage to Teeth

Illustration 43	g06324678
Typical example of spline damage from poor handling, but no signs of cracking. Use a polishing stone to smooth any raised material from the indentation, OK TO USE THIS PART AGAIN.

Illustration 44	g06324674
Typical example of spline damage from poor handling with a sign of cracking. Use a polishing stone to smooth any raised material from the indentation. If evidence of crack after removal of raised material, then DO NOT USE THIS PART AGAIN.

Illustration 45	g03680795
A spline is cracked in the area of the root and the crack has progressed into the adjacent splines, DO NOT USE THIS PART AGAIN.

Crack from Fatigue on Spindles

Operational loads create tensile stress in the fillet area on the loaded side of a tooth. With enough high loads and cycles, these stresses can cause fatigue cracks. A fatigue crack will develop until the tooth weakens enough to separate from the parent metal.

Numerous broken spline teeth may be the result of failure from bending fatigue. The operational loads create tensile stress in the fillet on the loaded side of the tooth. With enough high loads and cycles, these stresses can cause cracks from fatigue. A crack from fatigue could cause a tooth to separate from the parent metal. Cracking can also occur between the root of the tooth and a bolt hole or inside diameter of the part.

Illustration 46	g06324684
Typical example of a crack extending from the spline into the bolt hole. The bolt hole is weakened and premature failure will result, DO NOT USE THIS PART AGAIN.

Illustration 47	g06324686
Typical example of a crack in the root of the spline tooth, DO NOT USE THIS PART AGAIN.

Measurement Techniques

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° C (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° C (68° F). Ensuring that both the surface and core of the material is at the same temperature will increase the accuracy of the measurement taken.

Measurement Tooling Calibration

Outside Micrometers

Illustration 48	g06208395
Typical example of calibrating outside micrometer (A). (A) Outside Micrometer

Measurement Tooling include precision inside and outside diameter micrometers capable of measuring four decimal places in inches or three decimal places in millimeters. Measurement Tooling should be calibrated using gauge blocks certified to a national standard such as the National Institute of Standards and Technology (NIST).

Dorsey Carbon Fiber Snap Gages

Carbon fiber snap gages are available for measuring bearing journal diameters, refer to Table 5 for gage sizes.

Table 5

Dorsey Metrology International Carbon Fiber Snap Gages
Part Number	Gage Size
90141	425.415 ± 0.025 mm (16.7486 ± 0.0010 inch)
92268-2	288.895 ± 0.025 mm (11.3738 ± 0.0010 inch)
92270-2	234.92 ± 0.025 mm (9.249 ± 0.0010 inch)
92531-2	317.457 ± 0.025 mm (12.4983 ± 0.0010 inch)
92718-2	346.032 ± 0.025 mm (13.6233 ± 0.0010 inch)

Journal Diameters

Illustration 49	g06479496
Typical example of measuring an Outside Diameter (OD) Dimension of a spindle. (C) Indicates the diameter of the shaft. (D) Indicates the overall measurable length of the shaft journal.

Take measurements at locations (C1), (C2), and (C3).

Then take measurements at locations (C4), (C5), and (C6).

To ensure adequate life of the components, this document contains precise tolerances for measurements taken on various features. Ensure that several sample measurements are taken at different locations on the same feature. Measure diameters of journals in six places to identify tapered and or oval conditions. Refer to Illustration 49.

Spline Wear Measurement Procedures

This section provides the procedures that are necessary for you to measure both internal splines and external splines. This section will help you to calculate these measurements. Then, these results can be used to determine reusability of both internal splines and external splines on all Off-Highway Trucks.

• For the measurement of an external spline, calculate the average for the 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. Use the following procedure to determine the maximum allowable spline wear.

• Average the three dimensions to produce the average dimension over pins.

• For the measurement of an internal spline, calculate the average for the three measurements between pins. For each measurement, take the closest internal point between two pins that are 180° opposite of each other. Use the following procedure to determine the maximum allowable spline wear.

Gage Pins

For this procedure, each type of spline will require the use of a specific gage pin set. Refer to Tables 12 and 13 for gage pin dimensions. The gage pins are readily available commercially but if the gage pins are unavailable through your ordering system, then fabricate each gage pin for the specific gage pin set. Care must be taken to precisely machine these gage pins to specification due to the close tolerances of the gage pin diameters. If these gage pins are to be made, the use of 52100 alloy steel is recommended. The gage pin required Class is ZZ and have an allowed deviation of 0.00508 mm (0.00020 inch), geometry of 0.00254 mm (0.00010 inch), and a surface texture of 0.2540 μm (10.00000 μinch) Ra.

Methods of Securing Gage Pins

Illustration 50	g06075262
Typical example of MOP. (N) Rubber Band (P) Gage Pins

Note: Rubber band (N) can be used to secure gage pins (P) in place when taking measurements of external splines. Refer to Illustration 50.

Illustration 51	g06124082
Typical example of a magnetizer/ demagnetizer.

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NOTICE
If gage pins are magnetized, then demagnetize after use. When a gage pin is magnetized, cuttings and iron powder will easily stick to the surface, thus precipitating wear.

Gage pins can be magnetized to aid in taking measurements between or over gage pins. Ensure that gage pins are demagnetized after use and stored properly.

Illustration 52	g06075285
Typical example of taking a Measurement Over Pins (MOP). (R) Gage Pin (S) Magnet

Note: Magnet (S) is another method that can be used to keep gage pins (R) in place when taking measurements. Refer to Illustration 52.

External Spline

Illustration 53	g06321303
Typical wear step on an external spline.

Illustration 54	g06322365
Typical example of using a straight edge to measure a wear step on a spline tooth.

If possible, use a straight edge and a feeler gauge to measure questionable spline wear.

Illustration 55	g01716121
Typical example of a wear step. A 0.152 mm (0.0060 inch) wear step is required to stop a seal pick. If the wear step is greater than 0.203 mm (0.0080 inch), then DO NOT USE THE PART AGAIN.

Illustration 56	g06075290
Typical example of taking a Measurement Over Pins (MOP).

Illustration 57	g06181327
(L) 1, (L) 2, and (L) 3 Measurement Locations

The location of gage pins at 60° intervals is critical to the formula. These three locations will provide information about the wear of the part. Refer to Illustration 57.

Note: For odd splines take measurement as close to 180° from each gage pin as possible.

Place gage pins at 60° intervals on the spline. Take the measurements over gage pins that are located approximately 180° away from each other.

A micrometer must be positioned to measure the highest external points on the gage pins. This procedure will provide the measurement of the wear of the spline. The gage pin diameter for each individual part is determined by the size and pitch of the spline. Calculate the average from the values taken. The difference between the measurements will determine if there is an out of round condition caused by poor load distribution on the splines.

Steps 1 through 4 demonstrate an example of the process to calculate external spline roundness. Provided is an example of performing spline reusability calculations.

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NOTICE
The spline must pass the roundness tests by meeting the reusability specification measurement over gage pins and the maximum difference between the high and low measurements to be reused again.

1. Take measurements at locations (L) ₁, (L) ₂, and (L) ₃ over gage pins. Taken measurements are recorded in Table 6.
   Show/hide table

   Table 6

   External Spline Example of Recording 3 Measurements Taken
   Location	Measurements Taken
   L1	Ø 299.000 mm (11.7716 inch)
   L2	Ø 298.900 mm (11.7677 inch)
   L3	Ø 298.800 mm (11.7638 inch)

2. Add the measurements together to calculate the sum. The sum of the three measurements is 896.700 mm (35.3031 inch).
   Show/hide table

   Table 7

   External Spline Example of Calculating Sum of 3 Measurements Taken
   Measurement Locations	Calculation	SUM Total =
   L1, L2, and L3	L1 + L2 + L3	896.700 mm (35.3031 inch)

3. Divide the sum of the measurements taken by 3 to calculate the average. The calculated average of 298.900 mm (11.7677 inch) is greater than the reusability specification of 298.781 mm (11.7630 inch). In this example the external spline is within the reusability specification and therefore passes this test, proceed to Step 4.

   If the external spline is less than the reusability specification, then DO NOT USE THE PART AGAIN.

   Show/hide table

   Table 8

   External Spline Example of Calculating the Average of 3 Measurements Taken
   Location	Calculations	Results
   L1, L2, and L3	(L1 + L2 + L3) / 3 = Avg	Ø 298.900 mm (11.7677 inch)
   Refer to Specifications in Table 12.	Reusability Specification	Ø 298.781 mm (11.7630 inch)
   Avg Specification	Avg < Reusability Specification = Fail Avg > Reusability Specification = Pass	Avg = Ø 298.900 mm (11.7677 inch) > than Reusability Specification of Ø 298.781 mm (11.7630 inch) Pass

4. The difference between the high measurement and the low measurement determines if the spline is round. Out-of-round or ovality can cause uneven load distribution on the splines. Calculate the difference between the high and the low measurement by subtracting the high measurement of Ø 299.000 mm (11.7716 inch) from the low measurement of Ø 298.800 mm (11.7638 inch). The difference between the high and low measurement determine if the spindle can be reused. The difference in this example is 0.200 mm (0.0079 inch).

   Maximum difference between the high measurement and the low measurement allowance of 0.30 mm (0.012 inch) and the actual difference of 0.200 mm (0.0079 inch) is less than the allowable maximum difference.

   If the maximum difference between the high measurement and the low measurement is greater than 0.30 mm (0.012 inch) the external spline is considered to be out-of-round or oval shaped and not reusable, DO NOT USE PART AGAIN.

   Show/hide table

   Table 9

   External Spline Example of Determining the Difference from the 3 Measurements Taken
   Location	Calculations	Results
   L1	High	Ø 299.000 mm (11.7716 inch)
   L3	Low	Ø 298.800 mm (11.7638 inch)
   L1 - L3	High and Low Difference =	0.200 mm (0.0079 inch)
   Refer to Specifications in 12.	Maximum Difference Allowance	0.30 mm (0.012 inch)
   Actual Difference (H - L) Maximum Difference Allowance	Actual Difference > Maximum Difference Allowance = Fail Actual Difference < Maximum Difference Allowance = Pass	Actual Difference = 0.200 mm (0.0079 inch) < than Maximum Difference Allowance of 0.30 mm (0.012 inch) Pass

Spindle Bearing Journal Dimensions and Tolerances

Measure the diameter of the spindle at each bearing journal. Refer to Tables 10 and 11 for dimensions. The acceptable tolerance for reusability (without salvage) of bearing journals is “+ 0.025 mm (0.0010 inch) - 0.050 mm (0.0020 inch).”

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NOTICE
DO NOT confuse reusability tolerances with acceptable dimensions and tolerances used for machining of a spindle after salvaging.

Type 1 Rear Spindle Assembly

If the following areas on a Type 1 spindle show significant wear, thermal spray can be used for the repair of bearing journal surfaces on spindles. Both Arc Spray and HVOF are acceptable processes for this rework.

Note: Only AVSpare dealers may utilize applications for Thermal Spray. The processes must be carried out within the facilities of the dealership. The dealership must maintain a clean environment. The dealership must always use the correct equipment for all processes in each Thermal Spray Application.

Illustration 58	g06480911
Type 1 spindle measurement locations, refer to Table 10 for dimensions. (A) Length (B) Length (C) Diameter (D) Diameter (E) Seal Journal (F) Diameter (G) Bearing Journal (H) Bearing Journal (J) Mounting Flange Bolt Hole (K) Brake Flange Face (L) Face

After the repair is complete, mount the spindle assembly on a lathe. Zero the part on diameter (D) and brake flange face (K).

Bearing journals (G), (H), and seal journal (E) must be concentric within 0.08 mm (0.003 inch) Total Indicator Runout (TIR).

Face (L) must be perpendicular to bearing journals (G), and (H) within 0.30 mm (0.0118 inch) TIR, refer to Illustration 58.

Table 10

Type 1 Spindle Acceptable Dimensions and Tolerances
Part Number	Length (A)	Length (B)	Diameter (C)	Diameter (D)	Diameter (F)	Seal Journal (E)	Bearing Journals (G & H) Surface Texture - 1.6 µm (63 µinch)	Mounting Flange Bolt Hole (J)
2G-3479 5T-2378	288.14 ± 0.20 mm (11.344 ± 0.008 inch)	474.7 ± 0.5 mm (18.69 ± 0.02 inch)	Ø 508.0 ± 12.7 mm (20.00 ± 0.50 inch)	Ø 456.311 ± 0.051 mm (17.9650 ± 0.0020 inch)	Ø 311.150 + 0.025 / - 0.050 mm (12.2500 + 0.0010 / - 0.0020 inch)	Ø 361.95 ± 0.08 mm (14.250 ± 0.0032 inch)	Ø 247.619 ± 0.025 mm (9.7488 ± 0.0010 inch)	Ø 26.975 + 0.50 / -.25 mm (1.062 +0.020 / -0.010 inch)
7D-2819	268.27 ± 0.20 mm (10.562 ± 0.008 inch)	474.7 ± 0.5 mm (18.69 ± 0.02 inch)	Ø 508.0 ± 12.7 mm (20.00 ± 0.50 inch)	Ø 409.575 ± 0.05080 mm (16.125 ± 0.002 inch)	Ø 311.150 + 0.025 / - 0.050 mm (12.250 + 0.001 / - 0.002 inch)	Ø 361.95 ± 0.08 mm (14.250 ± 0.003 inch)	Ø 247.619 ± 0.025 mm (9.7488 ± 0.0010 inch)	Ø 26.975 + 0.508 / -.25 mm (1.062 +0.020 / -0.010 inch)

Type 2 Rear Spindle Assembly

If the following areas on a Type 2 spindle show significant wear, thermal spray can be used for the repair of bearing journal surfaces on spindles. Both Arc Spray and HVOF are acceptable processes for this rework.

Note: Only AVSpare dealers may utilize applications for Thermal Spray. The processes must be carried out within the facilities of the dealership. The dealership must maintain a clean environment. The dealership must always use the correct equipment for all processes in each Thermal Spray Application.

Illustration 59	g06480914
Type 2 spindle measurement locations, refer to Table 11 for dimensions. (D) Diameter (G) Bearing Journal (H) Bearing Journal (J) Mounting Flange Bolt Hole (K) Brake Flange Face (M) Length (N) Chamfer

After the repair is complete, mount the spindle assembly on a lathe. Zero the part on diameter (D) and brake flange face (K).

Bearing journals (G) and (H) must be concentric within 0.0380 mm (0.0015 inch) Total Indicator Runout (TIR).

Brake flange face (K) must be perpendicular to bearing journals (G) and (H) within 0.0380 mm (0.0015 inch) TIR, refer to Illustration 59.

Table 11

Type 2 Spindle Acceptable Dimensions and Tolerances
Part Number (1)	Bearing Journal (G) Surface Texture - 1.6 µm (63 µinch)	Record Actual Measurements of Bearing Journal (G) Refer to the "Journal Diameters" section for the proper techniques and number of measurements to be taken.	Bearing Journal (H) Surface Texture - 1.6 µm (63 µinch)	Record Actual Measurements of Bearing Journal (H) Refer to the "Journal Diameters" section for the proper techniques and number of measurements to be taken.	Mounting Flange Bolt Hole (J)	Length (M)
2G-0705 7I-5633 106-6521 107-8540 110-0554 152-8881	Ø 269.845 ± 0.025 mm (10.6238 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 234.920 ± 0.025 mm (9.2488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	122.2 ± 0.5 mm (4.8110 ± 0.0197 inch)
2G-5549 5T-2993 179-0735	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 203.17 ± 0.025 mm (7.999 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 17.0 + 0.40 / -0.15 mm (0.67 + 0.016 / - 0.006 inch)	91.9 ± 0.5 mm (3.6181 ± 0.0197 inch)
3Q-5910 106-6522 107-8541	Ø 269.845 ± 0.025 mm (10.6238 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 234.920 ± 0.025 mm (9.2488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	122.2 ± 0.5 mm (4.8110 ± 0.0197 inch)
4C-1791 106-6525 107-8538 154-1385 179-0737	Ø 346.032 ± 0.025 mm (13.6233 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 317.457 ± 0.025 mm (12.4983 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.02 / - 0.010 inch)	170.0 ± 0.5 mm (6.6929 ± 0.0197 inch)
5D-6342	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 203.170 ± 0.025 mm (7.9988 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 13.49 + 0.40 / -0.15 mm (0.531 + 0.016 / - 0.006 inch)	91.9 ± 0.5 mm (3.6181 ± 0.0197 inch)
5T-2997 8W-0154	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.083 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
5T-3083 8X-8091	Ø 269.845 ± 0.025 mm (10.6238 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 234.920 ± 0.025 mm (9.2488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	122.2 ± 0.5 mm (4.8110 ± 0.0197 inch)
5T-5748 8X-8093 106-6526 107-8486 129-1625 142-5948 152-8885 179-0742	Ø 384.145 ± 0.025 mm (15.1238 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 380.97 ± 0.025 mm (14.999 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 34.0 + 0.50 / - 0.25 mm (1.34 + 0.020 / - 0.020 inch)	173.0 ± 0.5 mm (6.8110 ± 0.0197 inch)
6G-6574	Ø 346.032 ± 0.038 mm (13.6233 ± 0.0015 inch)	C1 = C2 = C3 =	Ø 317.457 ± 0.038 mm (12.4983 ± 0.0015 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	170.0 ± 0.5 mm (6.6929 ± 0.0197 inch)
7I-5445	Ø 247.620 ± 0.025 mm (9.7488 ± 0.001 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
8W-7079	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
8X-1067 106-6527 107-8484 113-6048	Ø 415.895 ± 0.025 mm (16.3738 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 415.894 ± 0.025 mm (16.3738 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.010 inch)	179.5 ± 0.5 mm (7.0669 ± 0.0197 inch)
8X-8092 106-6524 107-8539 131-2522 152-8883 179-0740	Ø 346.032 ± 0.038 mm (13.6233 ± 0.0015 inch)	C1 = C2 = C3 =	Ø 317.457 ± 0.038 mm (12.4983 ± 0.0015 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	170.0 ± 0.5 mm (6.6929 ± 0.0197 inch)
8X-9978 106-6523 107-8537 131-2523 154-0945 179-0738	Ø 346.032 ± 0.038 mm (13.6233 ± 0.0015 inch)	C1 = C2 = C3 =	Ø 317.457 ± 0.038 mm (12.4983 ± 0.0015 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	170.0 ± 0.5 mm (6.6929 ± 0.0197 inch)
9M-4966	Ø 204.770 ± 0.013 mm (8.0618 ± 0.0005 inch)	C1 = C2 = C3 =	Ø 203.175 ± 0.013 mm (7.9990 ± 0.0005 inch)	C1 = C2 = C3 =	Ø 13.49 + 0.40 / -0.15 mm (0.531 + 0.016 / - 0.006 inch)	96.0 ± 0.5 mm (3.7795 ± 0.0197 inch)
106-6520 179-0736	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
119-8611 152-8882	Ø 288.895 ± 0.025 mm (11.3738 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 234.92 ± 0.025 mm (9.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	116.9 ± 0.5 mm (4.6024 ± 0.0197 inch)
139-7621	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 39.0 + 0.50 / - 0.25 mm (1.54 + 0.020 / - 0.010 inch)	290.0 ± 0.5 mm (11.4173 ± 0.0197 inch)
139-9185	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.010 inch)	179.5 ± 0.5 mm (7.0669 ± 0.0197 inch)
144-0518	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.010 inch)	179.5 ± 0.5 mm (7.0669 ± 0.0197 inch)
152-8887	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.010 inch)	179.5 ± 0.5 mm (7.0669 ± 0.0197 inch)
154-1384	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.5 + 0.50 / - 0.25 mm (1.08 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
179-0744	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 415.874 ± 0.025 mm (16.3730 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.010 inch)	179.5 ± 0.5 mm (7.0669 ± 0.0197 inch)
190-6091	Ø 425.4 ± 0.025 mm (16.7480 ± 0.0009 inch)	C1 = C2 = C3 =	Ø 425.4 ± 0.025 mm (16.7480 ± 0.0009 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.0104 inch)	245.0 ± 0.5 mm (9.6457 ± 0.0197 inch)
219-6097	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 39.0 + 0.50 / - 0.25 mm (1.54 + 0.020 / - 0.010 inch)	290.0 ± 0.5 mm (11.4173 ± 0.0197 inch)
243-5212	Ø 209.52 ± 0.025 mm (8.249 ± 0.0020 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.24880 ± 0.0020 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.0200 inch)	70.0 ± 0.25 mm (2.7559 ± 0.0098 inch)
244-4964	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.00984 inch)	70.0 ± 0.25 mm (2.7559 ± 0.0098 inch)
247-0869	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 39.0 + 0.50 / - 0.25 mm (1.54 + 0.02 / - 0.010 inch)	290.0 ± 0.5 mm (11.4173 ± 0.0197 inch)
255-8868 356-1487	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
256-7834	Ø 288.895 ± 0.025 mm (11.3738 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 234.92 ± 0.025 mm (9.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	116.9 ± 0.5 mm (4.6024 ± 0.0197 inch)
271-3759	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.010 inch)	70.0 ± 0.25 mm (2.7559 ± 0.0098 inch)
271-3760	Ø 209.52 ± 0.025 mm (8.2488 ± 0.0009 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.2488 ± 0.0009 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.01969 / - 0.010 inch)	70.0 ± 0.25 mm (2.7559 ± 0.0098 inch)
278-3437	Ø 425.4 ± 0.025 mm (16.7480 ± 0.0009 inch)	C1 = C2 = C3 =	Ø 425.4 ± 0.025 mm (16.7480 ± 0.0009 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.29921 + 0.020 / - 0.00984 inch)	245.0 ± 0.5 mm (9.6457 ± 0.0197 inch)
278-8810	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 39.0 + 0.50 / - 0.25 mm (1.54 + 0.020 / - 0.010 inch)	290.0 ± 0.5 mm (11.4173 ± 0.0197 inch)
286-8076	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 39.0 + 0.50 / - 0.25 mm (1.54 + 0.020 / - 0.010 inch)	290.0 ± 0.5 mm (11.4173 ± 0.0197 inch)
303-2356 340-2515 361-8116	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.2489 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.010 inch)	70.0 ± 0.25 mm (2.7559 ± 0.0098 inch)
303-2357	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.010 inch)	70.0 ± 0.25 mm (2.7559 ± 0.0098 inch)
308-3167	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	107.5 ± 0.25 mm (4.2323 ± 0.0098 inch)
310-6105	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
310-6108	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	107.5 ± 0.25 mm (4.2323 ± 0.0098 inch)
310-6110	Ø 288.895 ± 0.025 mm (11.3738 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 234.92 ± 0.025 mm (9.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	116.9 ± 0.50 mm (4.6024 ± 0.0197 inch)
331-2534	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.2489 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.010 inch)	70.0 ± 0.25 mm (2.7559 ± 0.0098 inch)
339-4948 361-8117	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.010 inch)	102.5 ± 0.25 mm (4.0354 ± 0.0098 inch)
348-5491	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 27.0 + 0.50 / - 0.25 mm (1.06 + 0.020 / - 0.010 inch)	102.5 ± 0.25 mm (4.0354 ± 0.0098 inch)
352-0150	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	119.5 ± 0.5 mm (4.7047 ± 0.0197 inch)
352-0460	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	107.5 ± 0.25 mm (4.2323 ± 0.0098 inch)
352-0461	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 209.52 ± 0.025 mm (8.249 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	107.5 ± 0.25 mm (4.2323 ± 0.0098 inch)
367-7957	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 39.0 + 0.50 / - 0.25 mm (1.54 + 0.020 / - 0.010 inch)	290.0 ± 0.5 mm (11.4173 ± 0.0197 inch)
375-9996	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 560.0 ± 0.05 mm (22.0472 ± 0.0019 inch)	C1 = C2 = C3 =	Ø 39.0 + 0.50 / - 0.25 mm (1.54 + 0.020 / - 0.010 inch)	290.0 ± 0.5 mm (11.4173 ± 0.0197 inch)
385-0018	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	126.0 ± 0.25 mm (4.9606 ± 0.0098 inch)
396-2348	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 247.620 ± 0.025 mm (9.7488 ± 0.0010 inch)	C1 = C2 = C3 =	Ø 26.0 + 0.50 / - 0.25 mm (1.02 + 0.020 / - 0.010 inch)	126.0 ± 0.25 mm (4.9606 ± 0.0098 inch)
396-3286	Ø 425.4 ± 0.25 mm (16.7480 ± 0.0098 inch)	C1 = C2 = C3 =	Ø 425.4 ± 0.25 mm (16.7480 ± 0.0098 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.010 inch)	245.0 ± 0.5 mm (9.6457 ± 0.0197 inch)
497-3506	Ø 425.4 ± 0.25 mm (16.7480 ± 0.0098 inch)	C1 = C2 = C3 =	Ø 425.4 ± 0.25 mm (16.7480 ± 0.0098 inch)	C1 = C2 = C3 =	Ø 33.0 + 0.50 / - 0.25 mm (1.30 + 0.020 / - 0.010 inch)	245.0 ± 0.5 mm (9.6457 ± 0.0197 inch)

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

Spindle Spline Dimensions and Tolerances

Illustration 60	g06482120
Typical example of taking a Measurement Over Pins (MOP) (P) of spindle spline. (P) Measurement Over Pins (MOP)

Table 12

Spindle External Spline Acceptable Dimensions and Tolerances					Record Actual Dimensions Refer to the "Spline Wear Measurement Procedures" section for the proper techniques and number of measurements to be taken.
Part Number (1)	Gage Pin Diameter	Original Specification Measurement Over Gage Pins	Reusability Specification Measurement Over Gage Pins	Maximum Difference High and Low Measurement	Measurement (P)
2G-0705 7I-5633 106-6521 107-8540 110-0554 152-8881	Ø 4.7625 mm (0.18750 inch)	Ø 235.638 mm (9.2771 inch)	Ø 235.298 mm (9.2637 inch)	0.235 mm (0.0093 inch)	L1 = L2 = L3 =
2G-3479 5T-2378	Ø 4.7625 mm (0.18750 inch)	Ø 250.870 mm (9.8768 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
2G-5549 5T-2993 179-0735	Ø 4.7625 mm (0.18750 inch)	Ø 207.667 mm (8.1759 inch)	Ø 207.333 mm (8.1627 inch)	0.207 mm (0.0082 inch)	L1 = L2 = L3 =
3Q-5910 106-6522 107-8541	Ø 4.7625 mm (0.18750 inch)	Ø 235.638 mm (9.2771 inch)	Ø 235.298 mm (9.2637 inch)	0.235 mm (0.0093 inch)	L1 = L2 = L3 =
4C-1791 106-6525 107-8538 154-1385 179-0737	Ø 4.7625 mm (0.18750 inch)	Ø 316.880 mm (12.4756 inch)	Ø 316.537 mm (12.4621 inch)	0.316 mm (0.0124 inch)	L1 = L2 = L3 =
5D-6342	Ø 4.877 mm (0.19201 inch)	Ø 208.003 mm (8.1891 inch)	Ø 207.251 mm (8.1595 inch)	0.207 mm (0.0082 inch)	L1 = L2 = L3 =
5T-2997 8W-0154	Ø 4.877 mm (0.19201 inch)	Ø 251.206 mm (9.8900 inch)	Ø 250.780 mm (9.8732 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
5T-3083 8X-8091	Ø 4.7625 mm (0.18750 inch)	Ø 235.638 mm (9.2771 inch)	Ø 235.298 mm (9.2637 inch)	0.235 mm (0.0093 inch)	L1 = L2 = L3 =
5T-5748 8X-8093 106-6526 107-8486 129-1625 142-5948 152-8885 179-0742	Ø 4.7625 mm (0.18750 inch)	Ø 377.807 mm (14.8743 inch)	Ø 377.465 mm (14.8608 inch)	0.377 mm (0.0148 inch)	L1 = L2 = L3 =
6G-6574	Ø 4.7625 mm (0.18750 inch)	Ø 316.880 mm (12.4756 inch)	Ø 316.537 mm (12.4621 inch)	0.316 mm (0.0124 inch)	L1 = L2 = L3 =
7D-2819	Ø 4.7625 mm (0.18750 inch)	Ø 250.870 mm (9.8768 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
7I-5445	Ø 4.877 mm (0.19201 inch)	Ø 251.206 mm (9.8900 inch)	Ø 250.780 mm (9.8732 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
8W-7079	Ø 4.877 mm (0.19201 inch)	Ø 251.206 mm (9.8900 inch)	Ø 250.780 mm (9.8732 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
8X-1067 106-6527 107-8484 113-6048	Ø 6.3500 mm (0.25000 inch)	Ø 416.451 mm (16.3957 inch)	Ø 416.114 mm (16.3824 inch)	0.416 mm (0.0164 inch)	L1 = L2 = L3 =
8X-8092 106-6524 107-8539 131-2522 152-8883 179-0740	Ø 4.7625 mm (0.18750 inch)	Ø 316.880 mm (12.4756 inch)	Ø 316.537 mm (12.4621 inch)	0.316 mm (0.0124 inch)	L1 = L2 = L3 =
8X-9978 106-6523 107-8537 131-2523 154-0945 179-0738	Ø 4.7625 mm (0.18750 inch)	Ø 316.880 mm (12.4756 inch)	Ø 316.537 mm (12.4621 inch)	0.316 mm (0.0124 inch)	L1 = L2 = L3 =
9M-4966	Ø 4.877 mm (0.19201 inch)	Ø 208.003 mm (8.1891 inch)	Ø 207.251 mm (8.1595 inch)	0.207 mm (0.0082 inch)	L1 = L2 = L3 =
106-6520 179-0736	Ø 4.7625 mm (0.18750 inch)	Ø 250.870 mm (9.8768 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
119-8611 152-8882	Ø 4.7625 mm (0.18750 inch)	Ø 235.638 mm (9.2771 inch)	Ø 235.298 mm (9.2637 inch)	0.235 mm (0.0093 inch)	L1 = L2 = L3 =
139-7621	Ø 7.9375 mm (0.31250 inch)	Ø 563.151 mm (22.1713 inch)	Ø 561.823 mm (22.1190 inch)	0.562 mm (0.0221 inch)	L1 = L2 = L3 =
139-9185	Ø 6.3500 mm (0.25000 inch)	Ø 416.451 mm (16.3957 inch)	Ø 416.114 mm (16.3824 inch)	0.416 mm (0.0164 inch)	L1 = L2 = L3 =
144-0518	Ø 6.3500 mm (0.25000 inch)	Ø 416.451 mm (16.3957 inch)	Ø 416.114 mm (16.3824 inch)	0.416 mm (0.0164 inch)	L1 = L2 = L3 =
152-8887	Ø 6.3500 mm (0.25000 inch)	Ø 416.451 mm (16.3957 inch)	Ø 416.114 mm (16.3824 inch)	0.416 mm (0.0164 inch)	L1 = L2 = L3 =
154-1384	Ø 4.877 mm (0.19201 inch)	Ø 251.206 mm (9.8900 inch)	Ø 250.780 mm (9.8732 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
179-0744	Ø 6.3500 mm (0.25000 inch)	Ø 416.451 mm (16.3957 inch)	Ø 416.114 mm (16.3824 inch)	0.416 mm (0.0164 inch)	L1 = L2 = L3 =
219-6097	Ø 7.9375 mm (0.31250 inch)	Ø 563.151 mm (22.1713 inch)	Ø 561.823 mm (22.1190 inch)	0.562 mm (0.0221 inch)	L1 = L2 = L3 =
247-0869	Ø 7.9375 mm (0.31250 inch)	Ø 563.151 mm (22.1713 inch)	Ø 561.823 mm (22.1190 inch)	0.562 mm (0.0221 inch)	L1 = L2 = L3 =
278-8810	Ø 7.9375 mm (0.31250 inch)	Ø 563.151 mm (22.1713 inch)	Ø 561.823 mm (22.1190 inch)	0.562 mm (0.0221 inch)	L1 = L2 = L3 =
286-8076	Ø 7.9375 mm (0.31250 inch)	Ø 563.151 mm (22.1713 inch)	Ø 561.823 mm (22.1190 inch)	0.562 mm (0.0221 inch)	L1 = L2 = L3 =
367-7957	Ø 7.9375 mm (0.31250 inch)	Ø 563.151 mm (22.1713 inch)	Ø 561.823 mm (22.1190 inch)	0.562 mm (0.0221 inch)	L1 = L2 = L3 =
375-9996	Ø 7.9375 mm (0.31250 inch)	Ø 563.151 mm (22.1713 inch)	Ø 561.823 mm (22.1190 inch)	0.562 mm (0.0221 inch)	L1 = L2 = L3 =

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

Illustration 61	g06481513
Typical example of taking a Measurement Over Pins (MOP) of spindle spline (R) and (S). (R) Spline (Outer) (S) Spline (Inner)

Table 13

Spindle External Spline Acceptable Dimensions and Tolerances						Record Actual Dimensions Refer to the "Spline Wear Measurement Procedures" section for the proper techniques and number of measurements to be taken.
Part Number (1)	Location	Gage Pin Diameter	Original Specification Measurement Over Gage Pins	Reusability Specification Measurement Over Gage Pins	Maximum Difference High and Low Measurement	Measurement (R) & (S)
190-6091	R	Ø 8.0000 mm (0.31496 inch.)	Ø 426.451 mm (16.7894 inch)	Ø 426.109 mm (16.7759 inch)	0.426 mm (0.01677 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 557.190 mm (21.9366 inch)	Ø 556.643 mm (21.9150 inch)	0.556 mm (0.0219 inch)	L1 = L2 = L3 =
243-5212	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
244-4964	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
255-8868 356-1487	R	Ø 4.7625 mm (0.18750 inch)	Ø 251.020 mm (9.8827 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 384.962 mm (15.1560 inch)	Ø 384.421 mm (15.1347 inch)	0.384 mm (0.0151 inch)	L1 = L2 = L3 =
256-7834	R	Ø 4.7625 mm (0.18750 inch)	Ø 235.788 mm (9.2830 inch)	Ø 235.298 mm (9.2637 inch)	0.235 mm (0.0093 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 384.962 mm (15.1560 inch)	Ø 384.421 mm (15.1347 inch)	0.384 mm (0.0151 inch)	L1 = L2 = L3 =
271-3759	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
271-3760	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
278-3437	R	Ø 8.0000 mm (0.31496 inch.)	Ø 426.451 mm (16.7894 inch)	Ø 426.109 mm (16.7759 inch)	0.426 mm (0.0168 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 557.190 mm (21.9366 inch)	Ø 556.643 mm (21.9150 inch)	0.556 mm (0.0219 inch)	L1 = L2 = L3 =
303-2356 340-2515 361-8116	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
303-2357	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
308-3167	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.27367 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
310-6105	R	Ø 4.7625 mm (0.18750 inch)	Ø 251.020 mm (9.8827 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 384.962 mm (15.1560 inch)	Ø 384.421 mm (15.1347 inch)	0.384 mm (0.0151 inch)	L1 = L2 = L3 =
310-6108	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
310-6110	R	Ø 4.7625 mm (0.18750 inch)	Ø 235.788 mm (9.2830 inch)	Ø 235.298 mm (9.2637 inch)	0.235 mm (0.0093 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 384.962 mm (15.1560 inch)	Ø 384.421 mm (15.1347 inch)	0.384 mm (0.0151 inch)	L1 = L2 = L3 =
331-2534	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
339-4948 361-8117	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
348-5491	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
352-0150	R	Ø 4.7625 mm (0.18750 inch)	Ø 251.020 mm (9.8827 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 384.962 mm (15.1560 inch)	Ø 384.421 mm (15.1347 inch)	0.384 mm (0.0151 inch)	L1 = L2 = L3 =
352-0460	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
352-0461	R	Ø 4.000 mm (0.15748 inch)	Ø 210.492 mm (8.2871 inch)	Ø 210.149 mm (8.2736 inch)	0.210 mm (0.0083 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 303.479 mm (11.9480 inch)	Ø 303.139 mm (11.9346 inch)	0.303 mm (0.0119 inch)	L1 = L2 = L3 =
385-0018	R	Ø 4.7625 mm (0.18750 inch)	Ø 251.020 mm (9.8827 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 384.962 mm (15.1560 inch)	Ø 384.421 mm (15.1347 inch)	0.384 mm (0.0151 inch)	L1 = L2 = L3 =
396-2348	R	Ø 4.7625 mm (0.18750 inch)	Ø 251.020 mm (9.8827 inch)	Ø 250.531 mm (9.8634 inch)	0.250 mm (0.0098 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 384.962 mm (15.1560 inch)	Ø 384.421 mm (15.1347 inch)	0.384 mm (0.0151 inch)	L1 = L2 = L3 =
396-3286	R	Ø 8.0000 mm (0.31496 inch.)	Ø 426.451 mm (16.7894 inch)	Ø 426.109 mm (16.7759 inch)	0.426 mm (0.0168 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 557.190 mm (21.9366 inch)	Ø 556.85 mm (21.9232 inch)	0.556 mm (0.0219 inch)	L1 = L2 = L3 =
497-3506	R	Ø 8.0000 mm (0.31496 inch.)	Ø 426.451 mm (16.7894 inch)	Ø 426.109 mm (16.7759 inch)	0.426 mm (0.0168 inch)	L1 = L2 = L3 =
	S	Ø 8.0000 mm (0.31496 inch.)	Ø 557.190 mm (21.9366 inch)	Ø 556.85 mm (21.9232 inch)	0.556 mm (0.0219 inch)	L1 = L2 = L3 =

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

Salvage Procedures

Crack Inspection

Table 14

Spindles That Can Be Salvaged
Spindle Part Number
107-8540 110-0554 152-8881
107-8541
107-8538 154-1385 179-0737
5T-2997
107-8486 129-1625 142-5948 152-8885 179-0742
107-8484 113-6048
107-8539 131-2522 152-8883 179-0740
107-8537 131-2523 154-0945 179-0738
106-6520 179-0736
119-8611 152-8882
139-9185
144-0518
152-8887
154-1384
179-0744
190-6091
356-1487
256-7834
278-3437
278-8810
286-8076
361-8116
310-6110
361-8117
348-5491
352-0150
352-0460
352-0461
367-7957
375-9996
385-0018
396-2348

Table 15

Spindles That Can NOT Be Salvaged
Spindle Part Number
2G-0705 (1) 7I-5633 (1) 106-6521 (1)
2G-3479 5T-2378
2G-5549 5T-2993 179-0735
3Q-5910 (1) 106-6522 (1)
4C-1791 106-6525
5D-6342
8W-0154
5T-3083 (1) 8X-8091 (1)
5T-5748 8X-8093 106-6526
6G-6574
7D-2819
7I-5445
8W-7079
8X-1067 106-6527
8X-8092 106-6524
8X-9978 106-6523
9M-4966
139-7621 (1)
219-6097 (1)
243-5212
244-4964
247-0869 (1)
255-8868
271-3759
271-3760
303-2356 340-2515
303-2357
308-3167
310-6105
310-6108
331-2534
339-4948
396-3286
497-3506

(1)	This spindle requires a special salvage process and should be returned to Cat Reman if the core is acceptable

Table 16

Maximum Allowable Crack Length and Depth
Sales Model	Surface Crack Length	Crack Depth
777	100 mm (3.937 inch)	16 mm (0.630 inch)
785	100 mm (3.937 inch)	16 mm (0.630 inch)
789	125 mm (4.921 inch)	19 mm (0.748 inch)
793	125 mm (4.921 inch)	25 mm (1.00 inch)
797	150 mm (5.906 inch)	40 mm (1.575 inch)

Use the following criteria to determine if the cracks can be repaired.

1. Cracks must not extend through the entire section. Cracks must not be deeper than the dimensions in Table 16.

2. For maximum allowable crack length refer to Table 16.

3. Do not weld cracks in designated areas in Illustration 64 ,65, and 66.

Multiple Crack Criteria

Illustration 62	g03681149
Collinear if less than 45° angle. (A) 45°.

Two cracks close together are considered to be collinear (along the same line) if the angle between the two cracks is less than 45°.

Illustration 63	g03681152
Multiple Crack Criteria

• Example (1) Collinear within 25 mm (0.98 inch) diameter circle, treat as one crack.

• Example (2) Collinear outside 25 mm (0.98 inch) diameter circle, treat as two cracks.

• Example (3) Non-Collinear within 25 mm (0.98 inch) diameter circle, treat as two cracks.

• Example (4) Mixture of Collinear and Non-Collinear within 25 mm (0.98 inch) diameter circle. Treat the two collinear cracks as one crack. Treat the one non-collinear crack as one crack.

770-772, 773, 775, 777, and 785 Rear Spindle Crack Allowances

Weld repair is not allowed in Area (X) for the following models 770 - 772, 773, 775, 777, and 785. Crack allowances are not yet available for these models.

Illustration 64	g03681154
Area (X) includes the small radius inboard of the brake mounting flange or spline.

789, 793, and 797 Rear Spindle Crack Allowances

Illustration 65	g03681158
Typical view of a rear spindle with a spline style brake mounting. Inspection Zones: (A) ( B), (C), and (F) No Weld Zones: Area (X) ( A) Zone A (B) Zone B (C) Zone C (F) Zone F (Mounting Flange) (X) Area X

Illustration 66	g03681165
Typical view of a rear spindle with a flange style brake mounting Inspection Zones: (A) ( B), (C), and (F) No Weld Zones: Area (X) ( A) Zone A (B) Zone B (C) Zone C (F) Zone F (mounting flange) (X) Area X

For 789 spindles, minor grinding to reduce or remove cracks is acceptable in Zone (A) (between the journals), Zone (B), and Zone (C). Maximum grind depth without subsequent weld repair is 3.0 mm (0.12 inch) from original cast surfaces. Weld repair is required for areas excavated deeper than 3.0 mm (0.12 inch) from original cast surface. Maximum weld repairable crack dimensions are 125.00 mm (4.921 inch) long (measured prior to excavation) and 19.0 mm (0.75 inch) deep.

The spindle should be returned to Cat Reman for core credit if one or more of the following conditions apply:

• A crack remains after excavating 25.4 mm (1.00 inch) from original cast surface.

• Crack in either Zone (B) or Zone (C) is greater than 125.00 mm (4.921 inch) in length at maximum excavation depth of 25.4 mm (1.00 inch.)

• Zone (F) repair is required beyond what is allowed. Refer to Table 17 for more information on mounting flange.

Note: Zone (F): Minor cracks up to 3.0 mm (0.12 inch) in length and depth, subject to the multiple crack criteria defined in this document, may be ignored. Refer to Table 17 for more information on larger cracks.

Table 17

Sales Model	Measured Pre-Excavation Excavation Depth Zone E Maximum	Measured Pre-Excavation Repairable Crack Length Zone F Maximum	Measured Pre-Excavation Excavation Depth Zone G Maximum	Measured Pre-Excavation Excavation Depth Zone H Maximum	Excavation and Weld Repair Zone J Maximum Distance from the Edge of Mounting holes. (1)
789	24 mm (0.945 inch)	65 mm (2.559 inch)	4 to 6 mm (0.16 to 0.24 inch)	34 mm (1.339 inch)	13 mm (0.512 inch)
793	24 mm (0.945 inch)	70 mm (2.756 inch)	4 to 6 mm (0.16 to 0.24 inch)	33 mm (1.299 inch)	13 mm (0.512 inch)
797	38 mm (1.496 inch)	85 mm (3.346 inch)	4 to 6 mm (0.16 to 0.24 inch)	39 mm (1.535 inch)	13 mm (0.512 inch)

(1)	The ground weld repairs are to match original surfaces, avoiding removal of material outside of limits. Radius in corner must be restored to the original size.

Note: Multiple cracks and collinear cracks are special cases. Refer to "Multiple Crack Criteria" section.

789 Rear Spindle Crack Allowance for Zone A

1. If greater than 16.0 mm (0.63 inch) in length, grind and blend to 3.0 mm (0.12 inch) in depth (maximum), then if less than 16.0 mm (0.63 inch) in length, OK TO USE PART AGAIN.

789 Rear Spindle Crack Allowance Zone B and Zone C

1. No repair required for cracks 16.0 mm (0.63 inch) in length or less in Zone (B) or Zone (C).

2. Repair all cracks in Zone (B) and Zone (C) greater than 16.0 mm (0.63 inch) in length. Weld repair is required if crack is greater than 16.0 mm (0.63 inch) in length after grinding to a maximum of 9.0 mm (0.35 inch) in depth from the original surface. Refer to the "Special Crack Excavation for Zone F on 789, 793, and 797 Spindles" section.

793 Rear Spindle Crack Allowances

For 793 spindles, minor grinding to reduce or remove cracks is acceptable in Zone (A) (between the journals), Zone (B), and Zone (C). Maximum grind depth without subsequent weld repair is 3.0 mm (0.12 inch) from original cast surfaces. Weld repair is required for areas excavated deeper than 3.0 mm (0.12 inch) from original cast surface. Maximum weld repairable crack dimensions are 125.0 mm (4.921 inch) long (measured prior to excavation) and 25.4 mm (1.00 inch) deep.

The spindle should be returned to Cat Reman for core credit if one or more of the following conditions apply:

• A crack remains after excavating 25.4 mm (1.00 inch) from original cast surface.

• Crack in either Zone (B) or Zone (C) is greater than 125.0 mm (4.921 inch) in length at maximum excavation depth of 25.4 mm (1.00 inch).

• Zone (F) repair is required beyond what is allowed. Refer to Table 17 for more information on mounting flange.

Note: Zone (F): Minor cracks up to 3.0 mm (0.12 inch) in length and depth, subject to the multiple crack criteria defined in this document, may be ignored. Refer to Table 17 for more information on larger cracks.

Note: Multiple cracks and collinear cracks are special cases. Refer to the "Multiple Crack Criteria" section.

793 Rear Spindle Crack Allowance in Zone A

Show/hide table

Illustration 67	g03681170
Typical view of the lube slot located in Zone (A) on the spindle.

1. Grind and blend up to 3.0 mm (0.12 inch) in the depth. If remaining crack is less than 3.0 mm (0.12 inch), then OK TO USE PART AGAIN.

   Cracks in the lube slot can be removed with a proper mill cutter. Slot may be machined oversize up to 20.0 mm (0.79 inch) wide and 13.0 mm (0.51 inch) deep to remove cracks. Chamfer or deburr edges.

   Note: If the cracks remain after machining slot to maximum size, return spindle to Cat Reman.

   Note: Spindles with cracks extending through any edge to the bearing journal diameter must be returned to Cat Reman for repair.

793 Rear Spindle Crack Allowance in Zone B and Zone C

Illustration 68	g03681172
Top view looking down of a 793 spindle (X) Neutral Axis through Lube Hole (B1) ( C1) High Load Zone (B2) ( C2) Low Load Zone

Note: Zone (B1) and Zone (C1) are defined as the area between mounting holes 3 and 20 and mounting holes 28 and 45. Zone (B2) and Zone (C2) are defined as the area between mounting holes 19 and 29 and mounting holes 3 and 44. Refer to Illustration 68.

1. Repair all cracks in Zone (B1) and Zone (C1). No weld repair is required if the crack can be removed by grinding up to 3.0 mm (0.12 inch) in depth from the original surface. Blend smooth after grind repair.

2. No repair is required for cracks 16.0 mm (0.63 inch) in length or less in Zone (B2) and Zone (C2).

797 Rear Spindle Crack Allowances

For 797 spindles, minor grinding to reduce or remove cracks is acceptable in Zone (A) (between the journals), Zone (B), and Zone (C). Maximum grind depth without subsequent weld repair is 9.0 mm (0.35 inch) from original cast surfaces. Weld repair is required for areas excavated deeper than 9.0 mm (0.35 inch) from original cast surface. Maximum weld repairable crack dimensions are 150.0 mm (5.91 inch) long (measured prior to excavation) 40.0 mm (1.57 inch) deep.

The spindle should be returned to Cat Reman for core credit if one or more of the following conditions apply:

• A crack remains after excavating 40.0 mm (1.57 inch) from original cast surface

• Crack in either Zone (B) or Zone (C) is greater than 150.0 mm (5.91 inch) in length, at maximum excavation depth of 40.0 mm (1.57 inch)

• Zone (F) repair is required beyond what is allowed. Refer to Table 17 for more information on mounting flange.

Note: Zone (F): Minor cracks up to 3.0 mm (0.12 inch) in length and depth, subject to the multiple crack criteria described in this document, may be ignored. Refer to Table 17 for more information on larger cracks.

Note: Multiple cracks and collinear cracks are special cases. Refer to the "Multiple Crack Criteria" section.

797 Rear Spindle Crack Allowance for Zone A

1. If greater than 16.0 mm (0.63 inch) in length, grind and blend to 3.0 mm (0.12 inch) in depth (maximum), and if less than 16.0 mm (0.63 inch) in length, then OK TO USE PART AGAIN.

797 Rear Spindle Crack Allowance Zone B and Zone C

1. No repair required for cracks 16.0 mm (0.63 inch) in length or less in Zone (B) or Zone (C).

2. Repair all cracks in Zone (B) and Zone (C) greater than 16.0 mm (0.63 inch) in length. Weld repair is required if crack is greater than 16.0 mm (0.63 inch) in length after grinding to a maximum of 9.0 mm (0.35 inch) in depth from the original surface. Refer to the "Special Crack Excavation for Zone F on 789, 793, and 797 Spindles" section.

Crack Excavation

Once a crack has been detected the crack shall be removed by grinding, air carbon arc gouging, or machining. Cavities which have been gouged shall be chipped or ground to remove the gouging slag. Grind smooth all uneven areas caused by gouging which present pockets to trap slag. Non-Destructive Testing (NDT) shall be used to ensure that cracks have been removed, refer to the "Crack Detection Methods" section.

Note: Cover all exposed machined surfaces before beginning crack excavation.

Air Carbon-Arc Gouging

Illustration 69	g06085892
Air Carbon-Arc Gouging Equipment (A) Air Compressor (B) Power Source (C) Air and Power Connection (D) Hand Held Electrode Holder (E) Arc Gouging Electrode (F) Air Stream (G) Molten Material Removed from Work Piece (H) Work Piece (J) Work Lead

In many situations, the use of air-carbon arc gouging for the removal of defects is the best option. A significant advantage to the use of air-carbon arc gouging is the amount of metal which can be quickly removed. This process can also be used in locations which are not accessible to mechanical metal removers. Follow Steps 1 through 4 to obtain good results during the removal of defects with the air-carbon arc process:

1. All materials to be air-carbon arc gouged shall be preheated prior to gouging to 21 °C (70.0 °F).

2. The current ranges in Table 18 shall be used depending upon the carbon electrode diameter. A minimum open circuit voltage of 60 Volts shall be available.
   Show/hide table

   Table 18

   Air Carbon-Arc Gouging Information
   Electrode Diameter	Current Range (Amps, DC+)
   Ø 6 mm (1/4 inch)	300-400 A
   Ø 8 mm (5/16 inch)	350-450 A
   Ø 10 mm (3/8 inch)	450-600 A
   Ø 12 mm (1/2 inch)	800-1000 A

   Show/hide table

   Illustration 70	g06045852
   Gouging Operation (K) 25.4 mm (1.00 inch) (L) 50.8 mm (2.00 inch) (M) 6.35 mm (0.250 inch) (N) Plane of Crack (P) Layers

3. To prevent cracks from "running" during the air-carbon arc gouging operation, follow Steps 3a through 3c for crack removal.

   1. Starting in sound base metal approximately 25.4 mm (1.00 inch) from each end of the crack, gouge toward the center of the crack. The extent of metal removed should be approximately that shown in Illustration 70.

   2. Remove the remainder of the crack between the two gouged end areas to the same depth as the initial gouges.

   3. Repeat Steps 3a and 3b in layers approximately 6.35 mm (0.250 inch) deep until the crack is removed. Ensure to widen the groove toward the top surface as the depth increases per end view in Illustration 70.

4. MT to ensure that full crack is removed.

Weld Groove Preparation

Illustration 71	g03681122
Angle (Z) should be 30° for a crack that has a depth up to 38.0 mm (1.50 inch). Angle (Z) should be 45° for a crack that has a depth from 38.0 mm (1.50 inch) to 50.8 mm (2.00 inch).

Note: Be sure that the temperature of the base metal is at least 21 °C (70.0 °F). This temperature must be maintained throughout the cutting process. Protect the piece from drafts. This is especially important in cold weather.

1. After the crack has been removed, prepare the weld groove. Use a grinder to create an angle on the sidewall of the gouged section.

   Perform one of the following operations.

   • Any crack that has a depth of 38.0 mm (1.50 inch) or less is a small crack. To prepare the groove for a small crack, grind a 30° angle on the sidewall.

   • Any crack that has a depth that is between 38.0 mm (1.50 inch) and 51.0 mm (2.01 inch) is a large crack. To prepare the groove for a large crack, grind a 45° angle on the sidewall.

2. If necessary, use a grinder to dress the sides and the bottom of the weld joint. The weld must be free from carbon and rough edges. Ensure that the weld has a proper opening. Surfaces to be welded should be free from all rust, grease, oil, paint, or any other possible sources of moisture.

Special Crack Excavation for Zone F on 789, 793, and 797 Spindles

Note: Verify that the casting part number is listed in Table 14. Do Not proceed if the casting part number to be salvaged is not listed.

1. Verify that casting has been properly inspected by a qualified NDT specialist.

   Use wet magnetic particle testing for inspecting cracks before, during and after excavation to ensure that the crack has been fully removed.

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   Illustration 72	g06479271
   Spindle Crack Map (D) Lube Hole or Lube Slot (aligned with 6:00 o'clock position)

2. Locate cracks. Refer to Illustration 72 for Zone locations.

   Note: The 6:00 o'clock position is directly in line with the lube hole (D).

3. The spindle should be at ambient temperature of at least 20° C (68° F), before grinding or excavating the crack.
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   Illustration 73	g03681876
   Typical view of a 4.5 inch grinder.

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   Illustration 74	g03681881
   Typical view of a deburring tool. The guard has been removed for illustration purposes.

4. A deburring tool or a grinder is the only method approved for crack removal and excavation. Refer to Illustrations 73 and 74.

   Note: Always operate tooling using Personal Protection Equipment (PPE) and safety guards.

5. Fully remove cracks or reduce cracks to an acceptable length, depending on location. All weld repairs require complete removal of the crack, verified using the wet magnetic particle inspection process, before proceeding. Maximum weld repairable depth and length apply.

6. Once all the cracks are removed, use the wet magnetic particle testing process to ensure that cracks are fully removed before proceeding.

Illustration 75	g03681896
View of cracks before blending

Illustration 76	g03681901
View of cracks after blending

Illustration 77	g03681905
Excavation limits for 789, 793, 797, refer to Table 17 for the dimensions.

Illustration 78	g03681911
Edge of the mounting holes for 789, 793, and 797 refer to Table 17 for the dimensions.

Document the work order number, casting numeral code, serial number, spindle service hours, OR sequence number (if applicable), and the OR stamped numeral code in Table 19.

Table 19

Inspection Checklist	Check
Work Order Number
Truck Serial Number
Truck SMU, Hours
Cast Part Number
Cast Numeral Code
Pour Date (Refer to Table 20 Numeral Code Lookup)
Cast Serial Number
Spindle Service Hours
OR Stamped Part Number (If Applicable)
OR Stamped Sequence Number (If Applicable)

Table 20

Numerical Code Lookup
N	0
U	1
M	2
E	3
R	4
A	5
L	6
K	7
O	8
D	9

Record details of all cracks greater than 8.0 mm (0.31 inch) including surface length, subsurface length, and depth (when excavated), and location by zone and clock position. Subsurface length is defined as either the post-grind repair length or length remaining after excavating to maximum repairable depth.

Illustration 79	g06479271
Spindle Crack Map (D) Lube Hole or Lube Slot (aligned with 6:00 o'clock position)

Table 21

Weld #	Pre-Inspection	Weld Preparation	Weld Process	Zone	Radial Reference	Vertical Measure Reference	Angle Off Horizontal	Length of Weld	Depth of Weld	Date
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Table 22

Condition	789 / 797 Inspection Results (Pass/Fail)
	A	B	C
No Repair Required
Grind
Grind and Weld
Remove From Service

Note: Refer to the "793 Rear Spindle Crack Allowance in Zone B and Zone C" section locations of high load zones (B1), (B2) and low load zones (C1), (C2).

Table 23

Condition	793 Inspection Results (Pass/Fail)
	A	B1	B2	C1	C2
No Repair Required
Grind
Grind and Weld
Remove From Service

Salvage Welding

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. 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 cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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NOTICE
Weld repair should be done cautiously in certain locations as the heat can cause distortion in the case and pull components out of alignment. Generally, the larger the crack and weld repair, the more chance for developing distortion.

Weld repairs that do not get machined should be ground flush or shaped to match the profile of the surrounding material of gear case. There should be no visible defects present such as rollover, undercut, porosity, or slag inclusions. Ensure that each repair is inspected after the metal cools using either Liquid Penetrant Testing (PT) or Dry Magnetic Particle Testing (MT) methods. Refer to the "Crack Detection Methods" section.

Welder Qualifications

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a respirator for breathing protection.

Welders must be qualified for the appropriate type of weld that is being performed:

• Shielded Metal Arc Welding (SMAW)

• Flux Cored Arc Welding (FCAW)

• Gas Metal Arc Welding (GMAW)

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. The operator must wear the appropriate equipment. The operator must also install all appropriate equipment. All equipment must maintain the amount of fumes, heat, and ultraviolet radiation at a safe limit.

References:

• SEBD0512Reuse and Salvage Guidelines, "AVSpare Service Welding Guide"

• ANSI/ AWS D1.1, D14.3

• AVSpare Manufacturing Practice MC1000-105

Welding Materials and Specifications

Table 24

Process	FCAW	GMAW	SMAW
Filler/ Welding Materials, Gas/ Flux
Pass or layer Weld	All	All	All
Class	E90T1-D3C	ER80S/90S-D2	E10018-D2 (1) E11018-D2
AWS Standard	A5.29	A5.28	A5.5
Polarity	DCEP	DCEP	DCEP
Electrode Size Options
Electrode Diameter	Ø 1.6 mm (0.0625 inch) 1/16"	Ø 1.2 mm (0.045 inch)	Ø 3.2 mm (0.125 inch) 1/8"
Amps	230-250	275-300	100-120
Volts	28-30	27-30	N/A
Travel Speed	N/A	N/A	N/A
Diameter Alternate	Ø 2.4 mm (0.09375 inch) 3/32"	Ø 1.4 mm (0.052 inch)	Ø 4.8 mm (0.1875 inch) 3/16"
Amps	230-250	275-300	N/A
Volts	28-30	27-30	N/A
Travel Speed	NA	NA	N/A
Shielding Gas (Recommended)	100% CO2	Ar 90%- CO2 10%	N/A
Shielding Gas (Alternate)	Ar 90%- CO2 10%	Ar 75%- CO2 25%	N/A
Flow Rate	18 - 21 L/min (40 - 45 cfh)	18 - 21 L/min (40 - 45 cfh)	N/A N/A
Electrode Stick Out	12.70 to 19.05 mm (0.50 to 0.750 inch) 1/2-3/4"	12.70 to 19.05 mm (0.50 to 0.750 inch) 1/2-3/4"	N/A
Joint
Joint Design	Single V
Root Opening	0
Root Face	0
Buttering	N/A
Back Gouge Required	No
Backing Material	N/A
Position
Position of Groove	1G + 2G
Vertical Progression	N/A
Preheat
Preheat Temperature	200° C (392° F)
Method	Flame or Furnace (if available)
Interpass Temperature	200° C/ min (360° F)/ min
Post Weld Heat Treatment
Heating Rate	200° C/ hr (360° F)/ hr
Hold Temperature / Time	N/A
Cooling Rate	N/A
Comments	Slow Cool with insulated blanket
Weld Technique
Bead	Stringer
Initial / Interpass Cleaning	Chip, Needle Peen, or Wire brush
Back Gouge Method	NA
Comments	De-slag and or clean Every Pass
Inspection
Method	Visual, Wet Magnetic Particle

(1)	The E10018-D2 is a low hydrogen electrode. The electrode must be stored in an electrode oven at a temperature of 120 °C (248 °F) always. If a E10018-D2 electrode becomes damp, scrap the electrode, or recondition the electrode to manufacturer's specifications.

Flux-Cored Arc Welding CO₂

Equipment

Illustration 80	g06123326
Flux-Cored Arc Welding (FCAW) Equipment (A) Welding Electrode Spool (B) Wire Feeder (C) Gas Line-Out (D) Weld Gun Control Cable (E) Controller (F) Gas Line-In (G) Shielding Gas Tank (H) Power Cable (J) Ground Cable (K) Work Piece (L) Weld Gun

The flux cored arc welding - CO₂ shielded process requires a power source, wire feeder control, gun, and a system for supplying a shielding gas. A constant potential type power source is required to obtain the maximum efficiency from the flux cored arc welding process. This type of power source automatically supplies the correct amperage to maintain constant arc voltage. Most constant potential welding machines are rated 100% duty cycle at rated current. The power source should be rated equal to or above the highest volts and amperes specified by any welding procedure for which it is to be used. This practice provides a safety margin when the welding machines are operated for short periods of time at currents above the rated capacity. The main advantage provided by constant potential welding machines is the simplicity of the welding operation. The wire feed speed is adjusted to give the desired welding amperage which is automatically provided by the constant potential welding machine.

FCAW Consumables

The consumable welding materials involved in flux cored arc welding - CO₂ shielded, are a flux cored fabricated continuous wire type electrode and the CO₂ shielding gas.

The selection of the filler metal (electrode) is based on the composition of the base metal, the metal thickness, and type of joint, joint geometry, position of welding and the service requirements of the weldment. Refer to the weld parameter table located in the specific section to be welded for electrode specification and size.

Flux Cored Arc Welding (FCAW) electrodes are made in types to match practically all mild and low alloy steels. FCAW electrodes are available in 27 kg (60 lb) coils in diameters from 1.14 mm (0.045 inch) through 3.175 mm (0.1250 inch) (1/8") depending on the brand and type.

Carbon Dioxide Shielding Gas

Carbon dioxide used with the flux cored arc welding process must be "welding grade" because moisture in the gas will produce porous welds. "Welding grade" CO₂ has a dew point of - 40° C (40° F) or lower. When requested, the gas manufacturer shall furnish certification that the CO₂ will meet the dew point requirement.

Shielded Metal Arc Welding (SMAW)

SMAW Consumables (Electrodes)

The electrode is the only consumable involved in shielded metal arc welding. The selection of the electrode (filler metal) is based on the condition and composition of the base metal, the metal thickness, and type of joint, joint geometry, position of welding and the service requirements of the weldment.

Equipment

Illustration 81	g06123333
SMAW Equipment (M) Electrode Holder (N) Electrode Cable (P) Power Source (R) Ground Cable (S) Ground Cable or Lug Attached to Work Piece (T) Work Piece

The Shielded Metal Arc Welding (SMAW) process requires a power source, lead and ground cables, a ground clamp and electrode holder. The equipment is relatively simple and low in cost compared to most of the other welding processes. The SMAW process requires one of the following types of power sources.

• Direct Current (DC) Supply

• Alternating Current (AC) Supply

• Alternating Current (AC)/Direct Current (DC) Supply

Either type of power source is adequate for general-purpose welding. Direct current is often preferred for light articulate and/or out-of position welding because direct current produces a slightly smoother arc. Slightly higher deposition rates are possible with direct current, but this advantage is often offset by the disadvantage of greater arc blow.

Most electrodes are designed for DC or AC, although some types are designed for DC only.

Welding Preparation / Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

Preheating & Interpass Temperature

Note: Ensure that the temperature of the base metal is at least 21 °C (70.0 °F). This temperature must be maintained throughout the welding process. Protect the piece from drafts. This is especially important in cold weather. This temperature is required to avoid thermal shock. Do not confuse this temperature with the preheat temperature for the welding area.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Pre heat repair area approximately 101.6 mm (4.00 inch) in all directions from the prepared weld joint. The temperature for the preheat and post heat is between 200 to 230° C (392 to 446° F). The interpass temperature is also 200 to 230° C (392 to 446° F) and should be checked after each weld pass.

The preheat and interpass temperature shall be checked with a temperature indicating crayon prior to initiating the arc each pass.

Illustration 82	g06482218
(F) Infrared Thermometer (G) Temperature Indicating Crayon

Welding Techniques

Illustration 83	g06111648
Weld layer technique after crack excavation. (A) Weld Beads (B) Weld Layers

Welding technique (example: the manipulation of the welding electrode and deposition pattern of the weld metal), is important in producing a quality salvage weld. Weld beads can be placed as in Illustration 83 for crack repair.

1. Weld metal shall be deposited in weld beads and layers as shown in Illustration 83.

2. Puddling or continuing to weld with the electrode nearly stationary or in a tight circular pattern shall not be done.

3. The width of weld beads deposited in the vertical position of welding shall not exceed 1-1/2 times the width shown for the flat position. Do not weld in a vertical down progression.

4. The rate of travel and width of weaving shall be controlled to maintain the prescribed limits on the width of weld beads.

5. Tables 24 are suggested electrodes and parameters to be used during weld repairs.

Post Weld Treatments

Post Weld Treatments include the slow cooling, and finishing.

Slow Cooling

Illustration 84	g03824505
Typical example of a welding blanket.

Immediately after welding is complete, cover the weld with a welding blanket for slow cooling to reduce the chance of hydrogen cracking. The use of an insulated welding blanket is recommended to retain the heat.

Welding Procedure for Cracks in the Rear Spindle of 770 through 797 OHT

Protect machined surfaces from sparks. Protect the machined surfaces from the welding spatter.

1. Weld the spindle in a standard position (horizontal for 793 and below, vertical for 797).

2. For each weld pass, the fillet width must not exceed 8 mm (0.3 inch). Use stringer welds for each weld pass.

3. After each weld pass, needle peen the weld. Ensure that all the slag is removed.

4. Grind the crest of the weld to the original profile of the casting.

5. Visually inspect the weld and the surrounding area for defects.

6. After completing the repair, heat the weld area to 149° C (300° F) and allow the casting to cool slowly to room temperature.

Special Weld Procedure for Zone F on 789, 793, and 797 Spindles

1. For ease of welding and quicker repairs place the spindle in the horizontal position. The spindle in the horizontal position will aid in ergonomics.
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   Illustration 85	g03681922
   View of excavated crack with room to manipulate the weld arc.

2. Verify that the excavated area has been dressed so that there is enough room to weld.

   If the area being repaired has not been dressed appropriately, the welder performing the weld repair should grind the repair area to ensure full access and torch manipulation. Refer to Illustration 85.

   Note: The welder should make a final clean out pass with the deburring tool.

3. Once the area to be welded is repaired and has been fully excavated and dressed, use a ruler or tape measure and chalk to mark the 100 mm (4.00 inch) zone surrounding the excavation.
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   Illustration 86	g03681925
   Typical view of a rosebud torch.

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   Illustration 87	g03681935
   View of preheating the repair area.

4. Use a rosebud torch to preheat the marked zone to a temperature of 200° C (400° F) to 250° C (480° F). Verify the surface temperatures at the margins of the marked zone using the appropriate temperature stick or infrared gun. This temperature must be maintained throughout the weld process.
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   Illustration 88	g03681943
   Weld pass progression to fill the excavated crack.

5. Excavated cracks are to be repaired using a weld pass width no greater than 8.0 mm (0.31 inch). If one pass does not fill the repair, continue to weld until the excavated area is full.

   Note: Change directions of travel for each pass to stagger the stop and start points.

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   Illustration 89	g03681945
   Example of an incorrect weld with passes in one direction only and start/stop points not staggered.

6. Completely remove the slag after each weld pass and check the surface temperature near the weld to ensure interpass temperature of 200° C (400° F). If necessary, use the torch to reheat area to between 200° C (400° F) and 250° C (480° F) before the next pass.

7. When welding is complete, reheat the repaired area to a temperature between 200° C (400° F) to 230° C (450° F). Verify the surface temperature with the appropriate temperature stick or infrared gun.
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   Illustration 90	g03681946
   View of welding blanket covering the weld repair area after post-weld heating.

8. Cover the weld repair area with welding blankets immediately after post weld heating. The covered area should extend at least 300.0 mm (11.81 inch) in each direction beyond the weld repairs.

9. Allow the spindle to cool to a temperature of 38° C (100° F) or lower before removing the welding blankets.

10. Repeat Step 7 and Step8 for all weld repaired areas.

11. Grind the weld repair areas to approximate the original surface. Blend all welding transitions and grind areas with the original cast surface. Sharp edges or corners are not allowed.

12. Inspect the weld repairs a final time using wet magnetic particle to ensure weld quality.

13. Needle-peen the weld repair.

14. Wire brush Zone (B), Zone (C), and Zone (F) and clean.

15. Ensure that all weld spatter is removed from the spindle.
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    Illustration 91	g06482228
    (K) 40.0 mm (1.57 inch) Radius (L) Brake Anchor Pilot Diameter

16. If a repair is made in Zone (C), behind the brake flange then the radius must be ground to the original dimension (K) shown in Illustration 91. A template can easily be cut from cardboard for a reference.

17. Weld repairs which intersect the machined diameters on either side of the brake flange must be ground to approximate the original surface. Special care must be taken to avoid damaging the brake anchor pilot diameter (L) on Zone (B) side of the brake flange.

Run-Out Checks

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NOTICE
Check radial run-out to ensure that applicable components are within specification. Failure to check radial run-out will result in premature bearing failure.

Surface Texture Inspection & Testing

Weld repairs that do not get machined should be ground flush or shaped to match the profile of the surrounding material. Shaping can be done with a hand grinder and flexible sanding discs, however care must be taken not to contaminate the bearing components. The repair shall have no visible defects present such as rollover, undercut, porosity, or slag inclusions. Each repair should be inspected using NDT, refer to the "Crack Detection Methods" section.

Surface Texture Inspection

Illustration 92	g06130307
Typical example of checking surface texture using comparison gauge (A). (A) Comparison Gauge

Surface Texture Testing

Illustration 93	g06408018
Profilometer

Ensure that several samples are taken on machined journals using a surface texture tester to verify that the surface meets texture specifications. Refer to the specific component acceptable dimensions and tolerances table for surface texture specifications. For more information on surface texture.

Hardness Checks

Hardness should be measured using a suitable type hardness tester. Persons should be qualified or properly trained in how to use the hardness tester to ensure good results.

Preferred Option

Measure the hardness of bearing journals. The hardness must be at a minimum of 45 Rockwell C.

You may also use a C rated Rockwell tester. The tester must not leave marks. The GE MIC 10 measures in HRC and is the recommended tester for heat-treated materials, HVOF, and Arc Spray coatings.

The tolerance of the OD for each journal is + 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).

Alternative Option

Note: A minimum hardness reading of 45 Rockwell "C" (RC) or 430 Brinell (10 mm steel ball) is required.

Directions for using a Detroit Hardness Tester

Follow Steps 1 through 8 for using a Detroit Hardness Tester:

1. Locate area to be tested.

2. Use a non-metallic synthetic buffing wheel to clean bottom of grooves in area to be hardness tested.

3. Turn tester upside down allowing the ball to seat in the cap.
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   Illustration 94	g06398309
   Typical Example (E) Hardness Tester

4. Turn tester right side up and place on area that has been cleaned. Refer to Step 2.

5. Hold tester vertically and steady.

6. Slowly depress trigger, do not strike or you will get an inaccurate reading.

7. Read the top of the ball at the highest point of the ball's bounce.

8. Repeat Steps 3 through 7 for each test location three times to obtain an accurate reading.

Thermal Spray Procedures for OHT Rear Spindles

Preparation of a spindle is critical to achieve the desired bond and the desired finish of the coating.

Part Description

Table 25

Base Metal	Steel casting or forging
Hardness	28-34 rc

Arc Spray Equipment and Procedure

Table 26

Arc Spray Equipment
Maximum Surface Texture	1.6 µm (63 µinch)
Reason for Spraying	Wear or grooving
Mating Part Contact Area & Material	Inner bearing race
Arc Spray Equipment Type	SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 90MXC Wire Top 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	92.0 SMPM (300.00 SFPM)
Surface Preparation Method	Undercut and Grit blast if necessary
Equipment Required	Turn Vertical Lathe
Recommended Cutting Tool	ISCAR DNMG 432 TF IC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)

Table 27

Arc Spray Procedure
Arc Spray	Procedure		Check List
Clean Part	Degrease in hot caustic solution
Undercut	To "tru-up" surface
Chamfer	If required - 1.0 mm (0.039 inch) x 45°
Remove Oxide	Use fiber flap brush or Clean/strip disc
Clean Spray Area	Commercial degreaser
Mask for Grit Blaster	Duct Tape
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	Make sure that surface is clean
Mask for Metal Spray	Antibond or Blue Layout Dye
Metal Spray Equipment Type	Smart Arc 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 90 MXC	TAFA 90 MXC
Clamp Pressure	275 kPa (40 psi)
Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
Arc Load Volts	32V	32V
Amps	125 Amps	150 Amps
Gun to Work Distance (Standoff)	102 mm (4.0 inch)	102 mm (4.0 inch)
Spray Rate/Build Up	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
Rotation Speed of Part (RPM)	RPM varies depending on diameter (52 to 143 RPM)
Rotation Speed of Part	92.0 SMPM (300.00 SFPM)
Traverse Rate of Gun	11.0 SMPM (40.00 SFPM)
Gun Fixturing Method	Machine mount or hand held
Finishing Equipment	Lathe
Part/Cutter Rotation	Roughing 12.0 SMPM (40.00 SFPM) Finishing 15.0 SMPM (50.00 SFPM)
Coolant	Oil base synthetic - 40:1 ratio
Traverse Speed	0.30 mm (0.012 inch)
Depth of Rough Cut	0.38 mm (0.015 inch)
Depth of Finish Cut	0.25 mm (0.010 inch)

HVOF Spray Equipment and Procedure

Table 28

HVOF Spray Equipment
Maximum Surface Texture	1.6 µm (63 µinch) Ra 40 µm (1574.803 µinch) Rz
Reason for Spraying	Wear
Mating Part Contact Area & Material	Bearing
Oerlikon Metco Equipment Type	Diamond Jet Hybrid Spray System
Material	Metco 1008
Finish Thickness	As Required
Finishing Allowance	0.127 to 0.38 mm (0.005 to 0.015 inch) per side, as required
Spray Angle	90°
Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Lathe or headstock/ tailstock arrangement, rotary turntable
Rotation/Traverse Speed	45.7 SMPM (150.00 SFPM) Traverse rate of 5.00 mm (0.197 inch) per revolution
Surface Preparation Method	Machine to "tru-up" surfaces and Grit blast
Machining Method	Turn or Grind
Recommended Equipment	Turn (Lathe) / Grind (Finishers Tech)
Recommended Cutting Tool	Kennametal DNMP, Grade K313 or equivalent
Blast Media Recommendations	Pressure type Only (20 Mesh Aluminum Oxide Grit) Blast Profile: 6 µm (250 µinch) profile minimum
Finishing and Superfinishing Equipment Type	Diamond Belt Grinding
Grinding Equipment	Finishers Tech Super G-6 Belt Grinder or equivalent
Recommended Abrasive	3MTM TrizactTM Diamond Cloth Belts 663FC (70 micron)
Superfinishing Equipment	Supfina 210, IMPCO, GEM, or equivalent
Recommended Abrasive	3MTM Diamond Microfinishing Film (20 micron)
Remarks	If at anytime during spraying oil evolves from the casting, metal spraying must stop. Remove the coating and start the preparation procedure over from the beginning. If this is not done, the coating will fail during machining or during service.

Table 29

HVOF Spray Procedure
HVOF Spray Process (Hybrid Gun)	Salvage Procedure	Check List
Straighten Part	Step 1
Equipment Necessary
Maximum Runout Allowed
"Tru-up" Coating Surface	Step 2
Rotational and Positioner Equipment
Coolant
Grinding Requirements
Grinding Equipment	Finishers Tech Super G-6 grinding machine or equivalent
Contact Wheel	406 mm (16.0 inch) diameter, 1:2 ratio Scoop Wheel 45° serration, 90 Shore A hardness, 6.4 mm (0.25 inch) wider than belt
Contact Wheel vs. Rod Rotational Direction	Opposing Directions (Rotate towards the contact area)
Abrasive	3MTM CubitronTM Cloth Belts 966F 24 grit
Idler Force	70 - 100 lbs idler force per inch of belt width
Belt Speed	1830.0 SMPM (6000.00 SFPM)
Part Rotational Speed	25.0 SMPM (100.00 SFPM)
Rotation Speed Of Part (RPM)	RPM varies depending on diameter
Traverse Speed	6.0 mm (0.25 inch) per revolution
Turning Requirements
Recommended Cutter Grade	Kennametal DNMP, Grade K313 or equivalent
Part/Cutter Rotation (SFPM)	67 SMPM (220.00 SFPM)
Traverse Speed	0.2108 mm (0.00830 inch) per revolution
Depth Of Cut	0.38 to 0.51 mm (0.015 to 0.020 inch) per side, are required to "Tru-up"
Rotation Speed Of Part (RPM)	RPM varies depending on diameter
Clean the Spray Area	Step 3 A) Degrease in hot caustic solution or wipe with a degreasing agent B) Vapor degrease or set on a turntable and use a torch to heat to 120° C (248° F) to remove all oil from the castings pores. C) Drench bearing areas in Zep I.D. Red or equivalent
Surface Preparation (Grit Blaster)	Step 4
Mask For Blast	A) Mask off areas, leave 6.0 mm (0.25 inch) area of the spline exposed B) Add a graphite plug-in keyways and round edges to prevent shadowing during metal spray operation C) The bearing surfaces must be grit blasted to a roughness of 7.5 µm (300.00 µinch)
Blast Equipment	Pressure Type Only
Grit Type And Size	20 mesh Aluminum Oxide
Blast Profile	6 µm (250 µinch) profile minimum
Blast Air Pressure	689 kPa (100.0 psi)
Blast Nozzle to Work Piece Distance	51 to 127 mm (2.0 to 5.0 inch)
Remove Blast Masking	Remove blast-masking material and make sure that the surfaces are clean, but leave graphite plug in place
HVOF Coating	Step 5
HVOF Application of Coating	A) Install spindle into lathe or headstock/ tailstock arrangement. Set up shadow masks in front of spline area and at turnaround point. The shadow masks block heat transfer prevent overheating. Grit blast the shadow mask so that coating will adhere to the mask. Turn the shadow masks at a slight angle (20°) to prevent overspray from hitting the sprayed bearing surface. B) Perform a final degrease with trichloroethylene or Zep I.D. Red. Rotate the spindle during the degreasing operation. C) Monitor coating surface temperature with an optical pyrometer. Do not allow the spindle to reach 150° C (300° F). D) Every 10 passes stop spraying to allow cool down and check lathe chuck for tightness. E) Overspray the diameter to allow for cleanup and shrinkage upon cooling.
Refer to SEBF9236 for HVOF spray parameters.
HVOF Grinding Or Turning	Step 6
Rotational and Positioner Equipment	Lathe or headstock/ tailstock arrangement
Coolant	Use flood coolant of water with 5% Synthetic coolant such as Milicron 46C or equivalent.
Turning Requirements
Recommended Cutter Grade	Kennametal DNMP, Grade K313 or equivalent
Part/Cutter Rotation - Rough Cut	67 SMPM (220.00 SFPM)
Traverse Speed - Rough Cut	0.2108 mm (0.00830 inch) per revolution
Depth Of Cut - Rough Cut	0.076 mm (0.003 inch)
Rotation Speed Of Part (RPM) - Rough Cut	RPM varies depending on diameter
Final Pass Depth Of Cut For Finishing	0.0381 mm (0.00150 inch)
Turning Instructions
1) Leave the graphite plug in the keyway. Hand file the graphite plug flush with the coating. 2) Start cutting 6.35 mm (0.250 inch) from the edge of the coating and move the tool towards the end of the coating. Do not start at the end of the coating or the coating may lift. 3) Once a 6.35 mm (0.250 inch) wide band is cut, change directions and machine the remainder of the coating. 4) The machining can be performed dry, but a thin film of oil will increase insert life and provide a better surface finish.
HVOF Grinding Requirements
Grinding Equipment	Finishers Tech Super G-6 Grinding Machine
Contact Wheel	Plain face, Incompressible (Aluminum, steel or other), 6.4 mm (0.25 inch) wider than belt
Abrasive	3MTM TrizactTM Diamond Cloth Belts 663FC (70 micron)
Contact Wheel Vs. Rod Rotational Direction	Opposing Directions (Rotate towards the contact area)
Belt Speed	1830.0 SMPM (6000.00 SFPM)
Idler Force	70 - 100 lbs idler force per inch of belt width
Part Rotational Speed	23.0 SMPM (75.00 SFPM)
Rotation Speed Of Part (RPM)	RPM varies depending on diameter
Traverse Speed	6.0 mm (0.25 inch) per revolution
Infeed Per Pass (inches on diameter)	0.064 mm (0.0025 inch)
HVOF Superfinishing Requirements
Superfinishing Equipment	Supfina 210, IMPCO, GEM, or equivalent
Contact Wheel	Plain face, 60 Shore A hardness
Abrasive - HVOF Superfinishing	3MTM Diamond Microfinishing Film 675L (20 micron)
Contact Force	20-40 lbs
Abrasive Feed Rate	8.4 mm (0.33 inch) per minute
Belt Oscillation (Machine Setting)	Optional
Spindle Speed	92.0 SMPM (300.00 SFPM)
Rotation Speed Of Part (RPM)	RPM varies depending on diameter
Traverse Speed	1.5 mm (0.06 inch) per revolution

Note: Contact wheels are to be 6.0 mm (0.25 inch) wider than the belt to ensure that the belt width is supported evenly from edge-to-edge. Depth of cut for 3M^TMTrizact^TM Diamond Cloth Belts 663FC by grade (Depth of cut on the diameter per pass):

70 micron - 0.064 mm (0.0025 inch)

40 micron - 0.041 mm (0.0016 inch)

20 micron - 0.020 mm (0.0008 inch)

Table 30

Belt Roll Grinding Recommended Operating Parameters
Abrasive	3MTM TrizactTM Diamond Cloth Belts 663FC
Contact Wheel	Smooth Faced / Incompressible (Aluminum, 65 Shore D, Steel)
Belt Width	2 inches*
Belt Speed	6,000 SFPM
End of Roll Dwell	1/2 Overlap - 2 Revolutions
	Shoulder Grind - 5 revolutions
	* Wider belt allows faster traverse
	** Higher infeed traverse combinations have been achieved using cylindrical roll grinders
	=75 SFPM	=0.25 inch/rev.	Chrome Carbide (AVS)
			Grinding Infeeds
Rod Diameter	RPM	Traverse Rate	Infeed Per Pass (on diameter)
(inches)	(Workpiece)	(inch/min)	663FC 70-micron	663FC 40-micron	663FC 20-micron
Ø 1.50	191.0	47.7	0.0025	0.0017	0.0008
Ø 2.00	143.2	35.8	0.0025	0.0017	0.0008
Ø 2.50	114.6	28.6	0.0025	0.0017	0.0008
Ø 3.00	95.5	23.9	0.0025	0.0017	0.0008
Ø 3.50	81.9	20.5	0.0025	0.0017	0.0008
Ø 4.00	71.6	17.9	0.0025	0.0017	0.0008
Ø 4.50	63.7	15.9	0.0025	0.0017	0.0008
Ø 5.00	57.3	14.3	0.0025	0.0017	0.0008
Ø 5.50	52.1	13.0	0.0025	0.0017	0.0008
Ø 6.00	47.7	11.9	0.0025	0.0017	0.0008
Ø 6.50	44.1	11.0	0.0025	0.0017	0.0008
Ø 7.00	40.9	10.2	0.0025	0.0017	0.0008
Ø 7.50	38.2	9.5	0.0025	0.0017	0.0008
Ø 8.00	35.8	9.0	0.0025	0.0017	0.0008
Ø 8.50	33.7	8.4	0.0025	0.0017	0.0008
Ø 9.00	31.8	8.0	0.0025	0.0017	0.0008
Ø 9.50	30.2	7.5	0.0025	0.0017	0.0008
Ø 10.00	28.6	7.2	0.0025	0.0017	0.0008
Ø 10.50	27.3	6.8	0.0025	0.0017	0.0008
Ø 11.00	26.0	6.5	0.0025	0.0017	0.0008
Ø 11.50	24.9	6.2	0.0025	0.0017	0.0008
Ø 12.00	23.9	6.0	0.0025	0.0017	0.0008
Ø 12.50	22.9	5.7	0.0025	0.0017	0.0008
Ø 13.00	22.0	5.5	0.0025	0.0017	0.0008
Ø 13.50	21.2	5.3	0.0025	0.0017	0.0008
Ø 14.00	20.5	5.1	0.0025	0.0017	0.0008
Ø 14.50	19.8	4.9	0.0025	0.0017	0.0008
Ø 15.00	19.1	4.8	0.0025	0.0017	0.0008

Table 31

Superfinishing Chrome Carbide Recommended Operating Parameters
Abrasive	3MTM Diamond Microfinishing Film 675L (20 micron)
Film Feed Rate	0.33 inch/min
Applied Force	25 lb/inch
Oscillation	Low (Low/None: final pass)
Film Width	2 inch*
# of Passes	1 - 2 passes with a 25 - 35 Ra input finish**
Obtainable Surface Texture	3.0 - 6.0 µm (118.11 - 236.22 µinch) Ra
	* Wider film allows faster traverse
	** Finish obtained with 3MTM 663 FC 70 micron
		=300 SFPM		=0.0625 inch/rev.
Rod Diameter	RPM	Traverse Rate
(inches)	(Workpiece)	(inch/min)
Ø 1.50	Ø764.0	47.7
Ø 2.00	573.0	35.8
Ø 2.50	458.4	28.6
Ø 3.00	382.0	23.9
Ø 3.50	327.4	20.5
Ø 4.00	286.5	17.9
Ø 4.50	254.7	15.9
Ø 5.00	229.2	14.3
Ø 5.50	208.4	13.0
Ø 6.00	191.0	11.9
Ø 6.50	176.3	11.0
Ø 7.00	163.7	10.2
Ø 7.50	152.8	9.5
Ø 8.00	143.2	9.0
Ø 8.50	134.8	8.4
Ø 9.00	127.3	8.0
Ø 9.50	120.6	7.5
Ø 10.00	114.6	7.2
Ø 10.50	109.1	6.8
Ø 11.00	104.2	6.5
Ø 11.50	99.6	6.2
Ø 12.00	95.5	6.0
Ø 12.50	91.7	5.7
Ø 13.00	88.1	5.5
Ø 13.50	84.9	5.3
Ø 14.00	81.9	5.1
Ø 14.50	79.0	4.9
Ø 15.00	76.4	4.8

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

Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, and Dry/ Wet MT 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 32 for advantages and disadvantages and Table 33 for standards and requirements for these NDT methods.

Table 32

Crack Detection Methods Advantages vs. 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.

Table 33

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

Visual Testing (VT)

Illustration 95	g06085008
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 (E) Weld Size Inspection Gauges

Refer to Tooling and Equipment Table 3 for part numbers.

Components and welds that are to be tested using PT, MT, or UT shall first be subject to a Visual Testing (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration 95. 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 Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making 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: 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 96	g06103795
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 97	g06103803
   Typical example of applying penetrating oil to areas to be tested.

2. Apply penetrant by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrant 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 98	g06103816
   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 99	g06103820
   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 (8.0 - 12.0 inch) away from the testing area. Apply an even, thin layer of developer over the testing area. A few thin layers are a better application method than one thick layer.
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   Illustration 100	g06084042
   Typical example of cracks found during Liquid Penetrant Testing (PT).

5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 100. 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 Table 3 for part numbers.

Illustration 101	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 Table 3 for part numbers.

Illustration 102	g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MT). (B) Electromagnetic Yoke (D) Ultraviolet Lamp

Illustration 103	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 103. 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 104	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. See Illustration 104 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.