5/1/2021 SIS 2.

Thermal Spray Procedures of Differential Carrier Assemblies for Wheel Loader,

2020/08/12 Wheel Dozer, Compactor, Integrated Toolcarrier, Articulated Truck, and Wheel
Tractor Scraper (WTS) {0679, 3284} (SEBF2137)

SMCS - 0679,3284 i08198194

Articulated Truck
All

Integrated Toolcarrier
All
Landfill Compactor
826K (S/N: 2L31-UP; 2T61-UP)

Soil Compactor
825K (S/N: 2L91-UP; 2T91-UP)
Wheel Dozer
All

Wheel Loader
All
Wheel Tractor-Scraper
All

Introduction
Revision Summary of Changes in SEBF2137
Added part numbers 317-3021 and 8X-8089.
12 Changed part number 350-5713 to 370-5713.
Changed part number 8X-7754 to 8X-7764.
Added detail to summary of changes of revision -10 and changed title from
"Thermal Spray Procedures for Wheel Loader, Wheel Dozer, Compactor,
Integrated Toolcarrier, Articulated Truck, and Wheel Tractor Scraper -
11 Differential Carrier Assembly" to "Thermal Spray Procedures of Differential
Carrier Assemblies for Wheel Loader, Wheel Dozer, Compactor, Integrated
Toolcarrier, Articulated Truck, and Wheel Tractor Scraper (WTS)." Updated
References Table 2 and added blank cells to Tables 3,4, and 5.
Added 11 new serial number prefixes for New Product Introduction (NPI).
Corrected dimension for part number 528-3177 in Table 3.
10
Added Illustration 6 and Table 6 to cover articulated truck carrier housing
assembly.
Added new serial number prefixes for New Product Introduction.
09
Arranged tables in alpha numeric sequence.
Updated copyright and added serial numbers for effectivity and added 3 part
08
numbers
07 Added 2 part numbers.

Table 1

© 2020 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.
Unauthorized use of this document or the proprietary processes therein without permission
may be violation of intellectual property law.

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

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to
establish a parts reusability program. Reuse and salvage information enables Caterpillar
dealers and customers to benefit from cost reductions. Every effort has been made to
provide the most current information that is known to Caterpillar. Continuing improvement
and advancement of product design might have caused changes to your product which are
not included in this publication. This Reuse and Salvage Guideline must be used with the
latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical
Communicator (TC).

Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning
additional repair options or modifications to reuse and salvage techniques and/or methods.
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5/1/2021 SIS 2.0

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

form for feedback in the Service Information System (SIS web) interface.

Canceled Part Numbers and Replaced Part

Numbers
This document may include canceled part numbers and replaced part numbers. Use the
Numerical Part Record (NPR) on the Service Information System Website (SIS web) for
information about canceled part numbers and replaced part numbers. NPR will provide the
current part numbers for replaced parts.

Important Safety Information

Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are
caused by failure to observe basic safety rules or precautions. An accident can often be
avoided by recognizing potentially hazardous situations before an accident occurs. A person
must be alert to potential hazards. This person should also have the necessary training,
skills, and tools to perform these functions properly. Safety precautions and warnings are
provided in this instruction and on the product. If these hazard warnings are not heeded,
bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate
every possible circumstance that might involve a potential hazard. Therefore, the warnings
in this publication and the warnings that are on the product are not all inclusive. If a tool, a
procedure, a work method, or operating technique that is not recommended by Caterpillar is
used, ensure that it is safe for you and for other people to use. Ensure that the product will
not be damaged or the product will not be made unsafe by the operation, lubrication,
maintenance, or the repair procedures that are used.

Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair

on this product, until you have read and understood the
operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these
hazard warnings are not heeded, bodily injury or death could occur to you or to other
persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word”
such as “DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2 for an example of a
“WARNING” Safety Alert Symbol.

Illustration 2 g00008666

This safety alert symbol means:

Pay Attention!
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Become Alert!
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5/1/2021 SIS 2.0

Your safety is Involved.

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

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

Caterpillar cannot anticipate every possible circumstance that might involve a

potential hazard. The safety information in this document and the safety information
on the machine are not all inclusive. Determine that the tools, procedures, work
methods, and operating techniques are safe. Determine that the operation,
lubrication, maintenance, and repair procedures will not damage the machine. Also,
determine that the operation, lubrication, maintenance, and repair procedures will not
make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based
on information which was available at the time of publication. The specifications, torques,
pressures, measurements, adjustments, illustrations, and other items can change at any
time. These changes can affect the service that is given to the product. Obtain the
complete, most current information before you start any job. Caterpillar dealers can supply
the most current information.

Summary
This guideline provides the procedures necessary to determine the reusability of the
Differential Carrier Assembly. 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.

References
References
Media
Publication Type & Title
Number
"Why Reuse and Salvage Parts"
Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Reuse and Salvage Guidelines
SEBF9238
"Fundamentals of Arc Spray for reconditioning Components" (1)
Reuse and Salvage Guidelines
SEBF9240
"Fundamentals of Flame Spray for Reconditioning Components" (1)

Table 2
(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
https://sis2.cat.com/#/service-detail?
information which pertain to the components being repaired.
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5/1/2021 SIS 2.0

Specifications

Illustration 3 g03832003
Wheel Loader, Wheel Dozer, Integrated Toolcarrier, Articulated Truck, Load Haul Dump

Differential Carrier Assembly Acceptable Dimensions and Record Actual

Tolerances Dimensions

Part Dimension Dimension

Dimension A Dimension B
Number A B
Ø 214.630± 0.035 mm Ø 214.630 ± 0.035 mm
1S-3934
(8.4500 ± 0.0014 inch) (8.4500 ± 0.0014 inch)
Ø 219.520 ± 0.035 mm Ø 182.626 ± 0.035 mm
1S-3965
(8.6425 ± 0.0014 inch) (7.1900 ± 0.0014 inch)
Ø 231.648 ± 0.040 mm Ø 180.848 ± 0.036 mm
1V-7930
(9.1200 ± 0.0016 inch) (7.1200 ± 0.0015 inch)
Ø 165.000 ± 0.035 mm Ø 181.000 ± 0.035 mm
2V-3847
(6.4960 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
Ø 177.825 ± 0.035 mm Ø 181.000 ± 0.035 mm
2V-4462
(7.0010 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm
3K-2509
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 171.704 ± 0.038 mm Ø 209.296 ± 0.038 mm
3K-9405
(6.7600 ± 0.0015 inch) (8.2400 ± 0.0015 inch)
Ø 219.520 ± 0.035 mm Ø 182.626 ± 0.035 mm
3K-9450
(8.6425 ± 0.0014 inch) (7.1900 ± 0.0014 inch)
Ø 196.939 ± 0.038 mm Ø 160.076 ± 0.038 mm
3V-6668
(7.7535 ± 0.0015 inch) (6.3022 ± 0.0015 inch)
Ø 196.939 ± 0.038 mm Ø 160.076 ± 0.038 mm
3V-6669
(7.7535 ± 0.0015 inch) (6.3022 ± 0.0015 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm
3Y-9697
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 117.500 ± 0.035 mm Ø 117.500 ± 0.035 mm
3Y-9700
(4.6260 ± 0.0014 inch) (4.6260 ± 0.0014 inch)
Ø 215.925± 0.035 mm Ø 244.025 ± 0.040 mm
4E-2269
(8.5010 ± 0.0014 inch) (10.0010 ± 0.0016 inch)
Ø 215.925± 0.035 mm Ø 244.025 ± 0.040 mm
4E-2270
(8.5010 ± 0.0014 inch) (10.0010 ± 0.0016 inch)
Ø 129.992 ± 0.035 mm Ø 144.992 ± 0.035 mm
4V-5387
(5.1178 ± 0.0014 inch) (5.7083 ± 0.00145 inch)
Ø 114.985 ± 0.035 mm Ø 114.985 ± 0.035 mm
5G-4010
(4.5270 ± 0.0014 inch) (4.5270 ± 0.0014 inch)
Ø 171.704 ± 0.025 mm Ø 150.3680 ± 0.025 mm
5K-3511
(6.7600 ± 0.0010 inch) (5.9200 ± 0.0010 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm
5K-7828
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm
5K-7829
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
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Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm

5V-1277
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm
5V-5631
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 117.500 ± 0.035 mm Ø 117.500 ± 0.035 mm
6K-5624
(4.6260 ± 0.0014 inch) (4.6260 ± 0.0014 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm
6K-9975
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 203.200 ± 0.025 mm Ø 215.925 ± 0.035 mm
6M-1639
(8.0000 ± 0.0010 inch) (8.7600 ± 0.0010 inch)
Ø 214.630± 0.035 mm Ø 214.630 ± 0.035 mm
6M-1677
(8.4500 ± 0.0014 inch) (8.4500 ± 0.0014 inch)
Ø 203.200 ± 0.025 mm Ø 215.925 ± 0.035 mm
6S-0213
(8.0000 ± 0.0010 inch) (8.7600 ± 0.0010 inch)
Ø 115.011 ± 0.025 mm Ø 115.011 ± 0.025 mm
6S-3944
(4.5280 ± 0.0010 inch) (4.5280 ± 0.0010 inch)
Ø 129.992 ± 0.035 mm Ø 144.992 ± 0.035 mm
6W-1635
(5.1178 ± 0.0014 inch) (5.7083 ± 0.00145 inch)
Ø 133.375 ± 0.035 mm Ø 144.992 ± 0.035 mm
6W-5116
(5.2510 ± 0.0014 inch) (5.7083 ± 0.0014 inch)
Ø 254.025 ± 0.040 mm Ø 215.925 ± 0.035 mm
6W-8319
(10.0010 ± 0.0016 inch) (8.5010 ± 0.0014 inch)
Ø 231.648 ± 0.035 mm Ø 214.630 ± 0.035 mm
7K-8378
(9.1200 ± 0.0014 inch) (8.4500 ± 0.0014 inch)
Ø 214.630± 0.035 mm Ø 214.630 ± 0.035 mm
7K-8406
(8.4500 ± 0.0014 inch) (8.4500 ± 0.0014 inch)
Ø 114.985 ± 0.035 mm Ø 114.985 ± 0.035 mm
7V-2187
(4.5270 ± 0.0014 inch) (4.5270 ± 0.0014 inch)
Ø 240.015 ± 0.040 mm Ø 190.525 ± 0.035 mm
7V-9515
(9.4494 ± 0.0016 inch) (8.5010 ± 0.0014 inch)
Ø 177.825 ± 0.035 mm Ø 181.000 ± 0.035 mm
8R-2754
(7.0010 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
Ø 196.000 ± 0.025 mm Ø 170.000 ± 0.025 mm
8R-2756
(7.7165 ± 0.0010 inch) (6.6928 ± 0.0010 inch)
Ø 196.939 ± 0.038 mm Ø 160.076 ± 0.038 mm
8R-4767
(7.7535 ± 0.0015 inch) (6.3022 ± 0.0015 inch)
Ø 217.550 ± 0.040 mm Ø 247.675 ± 0.040 mm
8R-5896
(12.5019 ± 0.0016 inch) (9.7510 ± 0.0016 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.035 mm
8V-1105
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 165.000 ± 0.035 mm Ø 181.000 ± 0.035 mm
8V-7985
(6.4960 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
Ø 171.704 ± 0.038 mm Ø 209.296 ± 0.038 mm
9K-7680
(6.7600 ± 0.0015 inch) (8.2400 ± 0.0015 inch)
Ø 114.985 ± 0.035 mm Ø 114.985 ± 0.035 mm
9V-7607
(4.5270 ± 0.0014 inch) (4.5270 ± 0.0014 inch)
Ø 165.000 ± 0.035 mm Ø 180.000 ± 0.035 mm
9U-0473
(6.4960 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
Ø 206.400 ± 0.035 mm Ø 165.000 ± 0.035 mm
105-8710
(8.1260 ± 0.0014 inch) (6.4961 ± 0.0014 inch)
Ø 254.025 ± 0.040 mm Ø 215.925 ± 0.035 mm
119-6019
(10.0010 ± 0.0016 inch) (8.5010 ± 0.0014 inch)
Ø 254.025 ± 0.040 mm Ø 215.925 ± 0.035 mm
120-0259
(10.0010 ± 0.0016 inch) (8.5010 ± 0.0014 inch)
Ø 196.000 ± 0.025 mm Ø 170.000 ± 0.025 mm
145-0315
(7.7165 ± 0.0010 inch) (6.6928 ± 0.0010 inch)
Ø 206.400 ± 0.035 mm Ø 181.000 ± 0.035 mm
145-2436
(8.1260 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
Ø 206.400 ± 0.035 mm Ø 181.000 ± 0.035 mm
145-2437
(8.1260 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
Ø 196.000 ± 0.025 mm Ø 170.000 ± 0.025 mm
147-9952
(7.7165 ± 0.0010 inch) (6.6928 ± 0.0010 inch)
Ø 206.400 ± 0.035 mm Ø 181.000 ± 0.035 mm
147-9953
(8.1260 ± 0.0014 inch) (7.1260 ± 0.0014 inch)
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Ø 114.301 ± 0.013 mm Ø 114.301 ± 0.013 mm
164-9322
(4.5000 ± 0.0005 inch) (4.5000 ± 0.0005 inch)
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5/1/2021 SIS 2.0

Ø 177.825 ± 0.035 mm Ø 228.625 ± 0.035 mm

164-9324
(7.0010 ± 0.0014 inch) (9.0010 ± 0.0014 inch)
Ø 165.000 ± 0.035 mm Ø 206.400 ± 0.035 mm
173-0545
(6.4961 ± 0.0014 inch) (8.1260 ± 0.0014 inch)
Ø 196.000 ± 0.100 mm Ø 196.000 ± 0.100 mm
195-9710
(7.7165 ± 0.0039 inch) (7.7165 ± 0.0039 inch)
Ø 90.0 + 0.004 - 0.031 mm Ø 90.0 + 0.004 - 0.031 mm
210-8461
(3.543 + 0.00016 - 0.0012 inch) (3.543 + 0.00016 - 0.0012 inch)
Ø 165.000 ± 0.035 mm Ø 206.400 ± 0.035 mm
233-8629
(6.4961 ± 0.0014 inch) (8.1260 ± 0.0014 inch)
Ø 254.025 ± 0.040 mm Ø 215.925 ± 0.035 mm
237-5524
(10.0010 ± 0.0016 inch) (8.5010 ± 0.0014 inch)
Ø 90.0 + 0.004 - 0.031 mm Ø 90.0 + 0.004 - 0.031 mm
292-5391
(3.543 + 0.00016 - 0.0012 inch) (3.543 + 0.00016 - 0.0012 inch)
Ø 90.0 + 0.004 - 0.031 mm Ø 90.0 + 0.004 - 0.031 mm
292-5394
(3.543 + 0.00016 - 0.0012 inch) (3.543 + 0.00016 - 0.0012 inch)
Ø 90.0 + 0.004 - 0.031 mm Ø 90.0 + 0.004 - 0.031 mm
292-5437
(3.543 + 0.00016 - 0.0012 inch) (3.543 + 0.00016 - 0.0012 inch)
Ø 254.025 ± 0.040 mm Ø 215.925 ± 0.035 mm
346-4923
(10.0010 ± 0.0016 inch) (8.5010 ± 0.0014 inch)
Ø 177.825 ± 0.035 mm Ø 228.625 ± 0.04 mm
367-2017
(7.0010 ± 0.0014 inch) (9.00 ± 0.0016 inch)
Ø 177.825 ± 0.035 mm Ø 206.400 ± 0.035 mm
376-3748
(7.0010 ± 0.0014 inch) (8.1260 ± 0.0014 inch)
Ø 177.825 ± 0.035 mm Ø 228.625 ± 0.04 mm
378-3151
(7.0010 ± 0.0014 inch) (9.00 ± 0.0016 inch)
Ø 165.000 ± 0.035 mm Ø 206.400 ± 0.035 mm
381-1945
(6.4960 ± 0.0014 inch) (8.1260 ± 0.0014 inch)
Ø 165.000 ± 0.035 mm Ø 206.400 ± 0.035 mm
449-4608
(6.4960 ± 0.0014 inch) (8.1260 ± 0.0014 inch)
Ø 165.000 ± 0.035 mm Ø 206.400 ± 0.035 mm
449-4610
(6.4960 ± 0.0014 inch) (8.1260 ± 0.0014 inch)
Ø 215.925 ± 0.035 mm Ø 254.025 ± 0.040 mm
480-6732
(8.5010 ± 0.0014 inch) (10.0010 ± 0.0016 inch)
Ø 177.825 ± 0.035 mm Ø 228.625 ± 0.04 mm
528-3177
(7.0010 ± 0.0014 inch) (9.0009 ± 0.0016 inch)

Table 3

Illustration 4 g03334613
Articulated Truck

Articulated Truck Carrier Assembly Acceptable Record Actual

Dimensions and Tolerances Dimensions

Part Dimension Dimension

Dimension A Dimension B
Number A B
Ø 144.992 ± 0.035 mm Ø 129.992 ± 0.035 mm
7I-5791
(5.7083 ± 0.0014 inch) (5.1178 ± 0.0014 inch)
Ø 181.000 ± 0.035 mm Ø 165.000 ± 0.035 mm
8V-7985
(7.1260 ± 0.0014 inch) (6.4961 ± 0.0014 inch)
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Ø 144.992 ± 0.035 mm Ø 133.375 ± 0.035 mm

133-9856
(5.7083 ± 0.0014 inch) (5.2510 ± 0.0014 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
138-3615
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 176.600 ± 0.025 mm Ø 176.600 ± 0.025 mm
138-3689
(6.9528 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
165-1584
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 189.175 ± 0.025 mm
139-2140
(7.4478 ± 0.0010 inch) (7.4478 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 189.175 ± 0.025 mm
139-2162
(7.4478 ± 0.0010 inch) (7.4478 ± 0.0010 inch)
Ø 144.992 ± 0.035 mm Ø 133.375 ± 0.035 mm
141-1844
(5.7083 ± 0.0014 inch) (5.2510 ± 0.0014 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
143-8691
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
147-7388
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 189.175 ± 0.025 mm
160-8518
(7.4478 ± 0.0010 inch) (7.4478 ± 0.0010 inch)
Ø 176.600 ± 0.025 mm Ø 176.600 ± 0.025 mm
188-1000
(6.9528 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
188-1002
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
188-1499
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
188-1500
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 189.175 ± 0.025 mm Ø 176.600 ± 0.025 mm
188-1505
(7.4478 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 176.600 ± 0.025 mm Ø 176.600 ± 0.025 mm
317-3020
(6.9528 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 176.600 ± 0.025 mm Ø 176.600 ± 0.025 mm
317-3021
(6.9528 ± 0.0010 inch) (6.9528 ± 0.0010 inch)
Ø 165.025 ± 0.035 mm Ø 150.025 ± 0.035 mm
320-1106
(6.4970 ± 0.0014 inch) (5.9065 ± 0.0014 inch)
Ø 165.025 ± 0.035 mm Ø 150.025 ± 0.035 mm
320-1112
(6.4970 ± 0.0014 inch) (5.9065 ± 0.0014 inch)
Ø 165.0 ± 0.035 mm Ø 206.4 ± 0.035 mm
370-5713
(6.496 ± 0.0014 inch) (8.126 ± 0.0014 inch)
Ø 165.025 ± 0.035 mm Ø 206.40 ± 0.035 mm
365-3451
(6.4970 ± 0.0014 inch) (8.1260 ± 0.0014 inch)

Table 4

Illustration 5 g03832046
Wheel Tractor Scraper (WTS)

Wheel Tractor Scraper (WTS) Differential Carrier

Record Actual
Assembly Acceptable Dimensions and Dimensions
Tolerances

Part Dimension Dimension

Dimension A Dimension B
Number A B
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
5D-5466
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(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
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5/1/2021 SIS 2.0

Ø 241.300 ± 0.025 mm Ø 214.630 ± 0.025 mm

5D-5608
(9.5000 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 219.520 ± 0.025 mm Ø 182.626 ± 0.025 mm
5D-5855
(8.6425 ± 0.010 inch) (7.1900 ± 0.0010 inch)
Ø 133.375 ± 0.025 mm Ø 133.375 ± 0.025 mm
5K-7828
(5.2510 ± 0.0010 inch) (5.2510 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
5T-2967
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 219.520 ± 0.025 mm Ø 184.150 ± 0.025 mm
5T-3089
(8.6425 ± 0.010 inch) (7.2500 ± 0.0010 inch)
Ø 241.300 ± 0.025 mm Ø 214.630 ± 0.025 mm
5T-6587
(9.5000 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 133.375 ± 0.035 mm Ø 133.375 ± 0.025 mm
5V-1277
(5.2510 ± 0.0014 inch) (5.2510 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
6D-7372
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 241.300 ± 0.025 mm Ø 214.630 ± 0.025 mm
6D-8533
(9.5000 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
6G-3542
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
6G-9417
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
7D-1771
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 144.992 ± 0.035 mm Ø 148.455 ± 0.035 mm
7V-9595
(5.7083 ± 0.0014 inch) (5.8447 ± 0.0014 inch)
Ø 129.992 ± 0.038 mm Ø 129.992 ± 0.038 mm
8D-2755
(5.1178 ± 0.0015 inch) (5.1178 ± 0.0015 inch)
Ø 219.520 ± 0.025 mm Ø 184.150 ± 0.025 mm
8D-4199
(8.6425 ± 0.010 inch) (7.2500 ± 0.0010 inch)
Ø 129.992 ± 0.035 mm Ø 165.000 ± 0.035 mm
8V-9834
(5.1178 ± 0.0014 inch) (6.4960 ± 0.0014 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
8W-9898
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
8X-1116
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 241.300 ± 0.025 mm Ø 214.630 ± 0.025 mm
8X-7764
(9.5000 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 219.520 ± 0.025 mm Ø 184.150 ± 0.025 mm
8X-7765
(8.6425 ± 0.010 inch) (7.2500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
8X-8089
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
8X-7771
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
8X-9409
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 214.630 ± 0.025 mm Ø 214.630 ± 0.025 mm
9D-1029
(8.4500 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 241.300 ± 0.025 mm Ø 214.630 ± 0.025 mm
9D-6256
(9.5000 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 190.526 ± 0.025 mm Ø 165.026 ± 0.025 mm
230-1552
(7.5010 ± 0.010 inch) (6.4971 ± 0.0010 inch)
Ø 241.300 ± 0.025 mm Ø 214.630 ± 0.025 mm
244-6959
(9.5000 ± 0.0010 inch) (8.4500 ± 0.0010 inch)
Ø 190.526 ± 0.025 mm Ø 165.026 ± 0.025 mm
327-2759
(7.5010 ± 0.010 inch) (6.4971 ± 0.0010 inch)
Ø 215.925 ± 0.035 mm Ø 190.525 ± 0.035 mm
444-5201
(8.501 ± 0.0010 inch) (7.501 ± 0.0010 inch)

Table 5

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5/1/2021 SIS 2.0

Illustration 6 g06428232
Articulated Truck Carrier Housing Assembly

Articulated Truck Carrier Housing Assembly Acceptable Dimensions and Tolerances

Part
Dimension C Dimension D Dimension E Dimension F Dimension G Dimension H
Number
Ø Ø
160.5 ± 0.5 mm 163.0 ± 0.5 mm 157.0 ± 0.5 mm 159.5 ± 0.5 mm
435-7986 130.002 ± 0.025 mm 152.425 ± 0.025 mm
(6.319 ± 0.020 inch) (6.417 ± 0.020 inch) (6.181 ± 0.020 inch) (6.279 ± 0.020 inch)
(5.118 ± 0.001 inch) (6.001 ± 0.0001 inch)

Table 6

Thermal Spray Procedures

Part Description
Wheel Loader, Wheel Dozer, Articulated Truck, and Wheel Tractor Scraper:
Base
Ductile Iron
Metal
Integrated Toolcarrier: Cast Iron
Wheel Loader, Wheel Dozer, Articulated Truck, and Wheel Tractor Scraper:
Hardness 28-34 Rc
Integrated Toolcarrier: 156 - 217 BHN

Table 7

Arc Spray Equipment and Procedure

NOTICE
Mask off all surfaces that are not to be metal sprayed.

Arc Spray Information Details

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5/1/2021 SIS 2.0

Wheel Loader and Wheel Tractor Scraper: 6.0 µm

(240 µin)
Maximum Surface Texture Articulated Truck: 1.6 µm (63.00 µin)
Wheel Dozer and Integrated Toolcarrier: 3.5 µm
(138 µin)
Reason for Spraying Wear, grooving, or corrosion
Mating Part Contact Area &
Bearing
Material
SmartArc by Oerlikon Metco PPG Electric Arc Gun,
Arc Spray Equipment Type
TAFA 8830 MHU, or TAFA 8835 MHU
Wire TAFA 30T 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
148° C (300° F)
Spraying Not to Exceed
Auxiliary Cooling Filtered shop air
Lathe or headstock / tailstock arrangement, rotary
Rotation/Traverse Device
turntable
Rotation Speed 92 SMPM (300.00 SFPM)
Surface Preparation Method Undercut and Grit blast if necessary
Equipment Required Horizontal or Vertical Lathe
Recommended Cutting Tool ISCAR DNMG 432 TFIC507
Blast Media Recommendation Pressure Type Only (Aluminum Oxide Grit)
Before machining, bolt the caps into place to hold
Remarks
concentricity.

Table 8

Check
Arc Spray Procedure
List
Clean Part Degrease in hot caustic solution
Undercut If desired
Chamfer If required - 1.0 mm (0.039 inch) x 45°
Remove Oxide Use emery cloth or glass bead blaster
Clean Spray Area Commercial degreaser
Mask for Grit Blaster Duct tape, metal shield, or rubber
Grit Blast Equipment Pressure type only
Grit Type and Size 20 mesh aluminum oxide
Blast Air Pressure 690 kPa (100.0 psi)
Blast Nozzle to Work
51 mm to 150 mm (2.0 inch to 6.0 inch)
Distance
Remove mask material, make sure that surface is
Remove Blast Mask
clean
Mask for Metal Spray Duct tape, metal shield, or rubber
Metal Spray Equipment SmartArc by Oerlikon
TAFA
Type Metco
Consumable
TAFA 75B TAFA 75B
(Bondcoat)
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
128 mm (5.0 inch) 128 mm (5.0 inch)
(Standoff)
0.038 mm 0.038 mm
Spray Rate/Bond Pass
(0.0015 inch)/pass (0.0015 inch)/pass
Consumable (Topcoat) TAFA 30T TAFA 30T
Clamp Pressure 275 kPa (40 psi)
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Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
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5/1/2021 SIS 2.0

Arc Load Volts 31V 31V

Amps 150 Amps 175 Amps
Gun to Work Distance
166 mm (6.5 inch) 166 mm (6.5 inch)
(Standoff)
0.058 mm 0.058 mm
Spray Rate/Build Up
(0.0023 inch)/pass (0.0023 inch)/pass
Rotation Speed of Part
RPM varies depending on diameter
(RPM)
Rotation Speed of Part 92 SMPM (300 SFPM)
Traverse Rate of Gun 11 SMPM (40 SFPM)
Gun Fixturing Method Machine mount or hand held
Finishing Equipment Milling Machine or Lathe
Part/Cutter Rotation
50 SMPM (150 SFPM)
Roughing
Part/Cutter Rotation
75 SMPM (250 SFPM)
Finishing
Coolant Oil base synthetic - 40:1 ratio
Traverse Speed 0.30 mm (0.012 inch)
Depth of Rough Cut 0.51 mm (0.020 inch)
Depth of Finish Cut 0.25 mm (0.010 inch)

Table 9

Flame Spray Equipment and Procedure

Flame Spray Information Details
Wheel Loader and Wheel Tractor Scraper:
6.0 µm (240 µin)
Maximum Surface Texture Articulated Truck: 1.6 µm (63.00 µin))
Wheel Dozer and Integrated Toolcarrier:
3.5 µm (138 µin)
Reason for Spraying Wear, grooving, or corrosion
Mating Part Contact Area & Material Bearing race
Metco Equipment Type 6PII by Oerlikon Metco
Metco Material Oerlikon Metco 453
Finish Thickness As Required
0.51 mm to 0.64 mm (0.020 inch to 0.025 inch)
Finishing Allowance
per side
Spray Angle 90°
66° C (150° F) Do not direct flame on area to
Substrate Pre-Heat Temperature
be sprayed
Substrate Temperature During Spraying
148° C (300° F)
Not to Exceed
Auxiliary Cooling If desired
Rotation/Traverse Device Lathe or turntable
Rotation/Traverse Speed 91.4 SMPM (300.00 SFPM)
Surface Preparation Method Undercut and Grit Blast
Finishing Method Machine
Machining Equipment Type Lathe or Horizontal Mill
Recommended Cutter Grade C-2, 883 Carboloy or equivalent
Before machining, bolt the caps into place to
Remarks
hold concentricity

Table 10

Flame Spray Process Check

Procedure
(6P) List
Clean Part Degrease in hot caustic solution
Undercut To "tru-up" surface
Chamfer If required - 1.0 mm (0.039 inch) x 45°
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5/1/2021 SIS 2.0

Remove Oxide Use fiber flap brush, Clean/strip disc

Clean Spray Area Oerlikon Metco cleaning solvent or equivalent
Mask for Blast Duct Tape
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
51 mm to 150 mm (2.0 inch to 6.0 inch)
Distance
Remove Blast Mask Remove mask, make sure that surface is clean
Mask for Spray Oerlikon Metco Antibond or blue layout dye
6PII by Oerlikon Metco Hand Held Thermo Spray
Spray Equipment Type
System
Auxiliary Cooling If desired
Nozzle 6P-C7A-K "K" Nozzle
Air Capacity/Pressure 6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure 210 kPa (30.0 psi)
Oxygen Flow 1190 L/h (42.0 cfh)
Fuel Gas Pressure 100 kPa (15.0 psi)
Fuel Gas Flow 1415 L/h (50.0 cfh)
Carrier Gas Pressure 380 kPa (55.0 psi)
Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build Up 5.5 kg (12 lb) per hour or 90 gm (3.2 oz) per min
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed of Part
RPM varies depending on diameter
(RPM)
Rotation Speed of Part 91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun 15.24 SMPM (50.000 SFPM)
Gun Fixturing Method Machine mount or hand held
0.10 mm to 0.15 mm (0.004 inch to 0.006 inch)
Top Coat/Thickness
per pass
Finishing Equipment Lathe or Horizontal Mill
Part/Cutter Rotation 91.4 SMPM (300.00 SFPM)
0.05 mm to 0.10 mm (0.002 inch to 0.004 inch)
Traverse Speed
per revolution
0.38 mm to 0.51 mm (0.015 inch to 0.020 inch)
Depth of Rough Cut
per side
0.25 mm to 0.38 mm (0.010 inch to 0.015 inch)
Depth of Finish Cut
per side
Alternate Finish Method Emery cloth for desired finish

Table 11

PIP-10594881
2021/01/05
12:52:57-03:00
i04823631
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Caterpillar:
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