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


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Inspection and Salvage of Rear Wheel Spindles for Certain Off-Highway Trucks {4201, 4205} [SEBF8083]
POWER TRAIN
WHEEL GP
Inspection and Salvage of Rear Wheel Spindles for Certain Off-Highway Trucks {4201, 4205}
1.1. Introduction
2.1. Canceled Part Numbers and Replaced Part Numbers
3.1. Important Safety Information
4.1. Summary
5.1. References
6.1. Service Advisories, Service Letters, and Technical Service Bulletins
7.1. Tooling and Equipment
8.1. Preparation Recommendations
9.1. Standardized Parts Marking Procedure
10.2. Example 1
11.2. Example 2
12.1. Identification of Spindle Type
13.1. Inspection
14.2. Wheel Bearing Journals
15.2. Normal Wear
16.2. Surface Damage
17.2. Brake Anchor Flange
18.2. Porosity of Spindles
19.3. Areas of Inspection
20.2. Splines
21.3. Signs of Potential Failure
22.3. Spline Wear and Misalignment
23.3. Normal Wear
24.3. Wear Steps
25.3. Corrosion and Pitting
26.3. Damage to Teeth
27.3. Crack from Fatigue on Spindles
28.1. Measurement Techniques
29.2. Measurement Tooling Calibration
30.3. Outside Micrometers
31.3. Dorsey Carbon Fiber Snap Gages
32.2. Journal Diameters
33.2. Spline Wear Measurement Procedures
34.3. Gage Pins
35.3. Methods of Securing Gage Pins
36.3. External Spline
37.1. Spindle Bearing Journal Dimensions and Tolerances
38.2. Type 1 Rear Spindle Assembly
39.2. Type 2 Rear Spindle Assembly
40.1. Spindle Spline Dimensions and Tolerances
41.1. Salvage Procedures
42.2. Crack Inspection
43.2. Multiple Crack Criteria
44.2. 770-772, 773, 775, 777, and 785 Rear Spindle Crack Allowances
45.2. 789, 793, and 797 Rear Spindle Crack Allowances
46.3. 789 Rear Spindle Crack Allowance for Zone A
47.3. 789 Rear Spindle Crack Allowance Zone B and Zone C
48.3. 793 Rear Spindle Crack Allowances
49.3. 793 Rear Spindle Crack Allowance in Zone A
50.3. 793 Rear Spindle Crack Allowance in Zone B and Zone C
51.3. 797 Rear Spindle Crack Allowances
52.3. 797 Rear Spindle Crack Allowance for Zone A
53.3. 797 Rear Spindle Crack Allowance Zone B and Zone C
54.2. Crack Excavation
55.3. Air Carbon-Arc Gouging
56.3. Weld Groove Preparation
57.3. Special Crack Excavation for Zone F on 789, 793, and 797 Spindles
58.2. Salvage Welding
59.2. Welder Qualifications
60.2. Welding Materials and Specifications
61.2. Flux-Cored Arc Welding CO<SUB>2</SUB>
62.3. Equipment
63.3. FCAW Consumables
64.3. Carbon Dioxide Shielding Gas
65.2. Shielded Metal Arc Welding (SMAW)
66.3. Equipment
67.2. Welding Preparation / Area Preparation
68.2. Preheating & Interpass Temperature
69.2. Welding Techniques
70.2. Post Weld Treatments
71.3. Slow Cooling
72.2. Welding Procedure for Cracks in the Rear Spindle of 770 through 797 OHT
73.2. Special Weld Procedure for Zone F on 789, 793, and 797 Spindles
74.1. Run-Out Checks
75.1. Surface Texture Inspection & Testing
76.2. Surface Texture Inspection
77.2. Surface Texture Testing
78.1. Hardness Checks
79.2. Preferred Option
80.2. Alternative Option
81.1. Thermal Spray Procedures for OHT Rear Spindles
82.2. Part Description
83.2. Arc Spray Equipment and Procedure
84.2. HVOF Spray Equipment and Procedure
85.1. Crack Detection Methods
86.2. Visual Testing (VT)
87.2. Liquid Penetrant Testing (PT)
88.3. Materials and Equipment Required
89.3. Procedure
90.2. Dry Magnetic Particle Testing (MT)
91.3. Materials and Equipment Required
92.3. Procedure
93.2. Wet Magnetic Particle Testing (MT)
94.3. Materials and Equipment
95.3. Procedure
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 1g02139237

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.

------ WARNING! ------

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 2g00008666

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


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

------ WARNING! ------

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.


------ WARNING! ------

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 3g06430973
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.


    Illustration 4g03794147
    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.


    Illustration 5g06139437
    (G) Typical example of chasing threaded holes.

  3. Remove any broken bolts, use appropriate thread taps to chase all threaded holes.


    Illustration 6g06139440
    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 7g03748255
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 8g03748362
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 9g06431017
Type 1 is a two-piece rear spindle. This spindle is used by certain 772, 773, and 775 Off-Highway Truck models.


Illustration 10g06479393
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.


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 11g06479376
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 12g03680466
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 13g03680470
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 14g03680472
Illustration 14 shows an inner bearing journal that exhibits normal wear, OK TO USE PART AGAIN.


Illustration 15g06430911
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 16g06430884
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 17g06430929
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 18g03680490
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 19g03680493
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 20g03680502
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 21g03680509
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 22g03680513
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 23g06430861
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 24g06430848
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 25g06482108
(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 26g06430812
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 27g06430823
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 28g06479324
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 29g06491316
( 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 30g03680722
( 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 31g03680726
( 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 32g06479347
( 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 33g06479364
( 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 34g06479402
( 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 35g01240365
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 36g03680790
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 37g06122435
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 38g06122438
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 39g06319105
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 40g06324680
Typical example of corrosion from poor storage techniques, clean inspect for pitting. If excessive pitting, then DO NOT USE THIS PART AGAIN.


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


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

Damage to Teeth



Illustration 43g06324678
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 44g06324674
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 45g03680795
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 46g06324684
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 47g06324686
Typical example of a crack in the root of the spline tooth, DO NOT USE THIS PART AGAIN.

Measurement Techniques


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 48g06208395
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 49g06479496
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 50g06075262
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 51g06124082
Typical example of a magnetizer/ demagnetizer.


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 52g06075285
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 53g06321303
Typical wear step on an external spline.


Illustration 54g06322365
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 55g01716121
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 56g06075290
Typical example of taking a Measurement Over Pins (MOP).


Illustration 57g06181327
(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.


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.

    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).

    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.

    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.

    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).”


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 58g06480911
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 59g06480914
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 60g06482120
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 61g06481513
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  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  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  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 
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  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  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  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  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 
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  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  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  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  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  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  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 
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  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  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  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  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  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  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  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  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 62g03681149
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 63g03681152
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 64g03681154
Area (X) includes the small radius inboard of the brake mounting flange or spline.

789, 793, and 797 Rear Spindle Crack Allowances



Illustration 65g03681158
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 66g03681165
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



    Illustration 67g03681170
    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 68g03681172
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 69g06085892
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.

    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 


    Illustration 70g06045852
    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 71g03681122
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.



    Illustration 72g06479271
    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.


    Illustration 73g03681876
    Typical view of a 4.5 inch grinder.


    Illustration 74g03681881
    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 75g03681896
View of cracks before blending


Illustration 76g03681901
View of cracks after blending


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


Illustration 78g03681911
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 

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 79g06479271
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 
                   
                   
                   
                   
                   
                   
                   
                   
                   
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
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

------ WARNING! ------

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


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 
Root Face 
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 80g06123326
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 81g06123333
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

------ WARNING! ------

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

Welding Techniques



Illustration 83g06111648
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 84g03824505
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.


    Illustration 85g03681922
    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.


    Illustration 86g03681925
    Typical view of a rosebud torch.


    Illustration 87g03681935
    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.


    Illustration 88g03681943
    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.



    Illustration 89g03681945
    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.


    Illustration 90g03681946
    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.


    Illustration 91g06482228
    (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


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

Surface Texture Testing



Illustration 93g06408018
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.


    Illustration 94g06398309
    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 3MTMTrizactTM 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


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 95g06085008
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)

------ WARNING! ------

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



    Illustration 96g06103795
    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.


    Illustration 97g06103803
    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.


    Illustration 98g06103816
    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.


    Illustration 99g06103820
    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.


    Illustration 100g06084042
    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 101g06085930
(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 102g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MT).
(B) Electromagnetic Yoke
(D) Ultraviolet Lamp


Illustration 103g06003178
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.


    Illustration 104g03536210

  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.

Information System:

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