Curso de Motores Sistema de Combustible - CAT

Procedure to Machine Damaged Transmission and Differential Yokes {3030,
2019/04/01
3253, 3258} (SEBF8048)
SMCS - 3258,3253,3030 i07713919

Agricultural Tractor
All
Articulated Truck
All
Backhoe Loader
All
Compact Wheel Loader
All
Integrated Toolcarrier
All
Landfill Compactor
816K (S/N: LT61-UP; SLL1-UP)
826K (S/N: 2L31-UP; 2T61-UP)
836K (S/N: T6X1-UP; L6Z1-UP)
Motor Grader
All
Off-Highway Truck/Tractor
69D (S/N: 9SS1-UP; 9XS1-UP)
73D (S/N: 9YS1-UP; 1GW1-UP)
768B (S/N: 79S1-UP)

768C (S/N: 02X1-UP)
769 (S/N: 99F1-UP; 35W1-UP)
769C (S/N: 01X1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770 (S/N: JND1-UP; M7W1-UP; BZZ1-UP)

770G (S/N: KD21-UP; RMA1-UP; TWA1-UP; RMD1-UP; KDH1-UP; ECM1-UP; ECX1-
UP)
772 (S/N: RLB1-UP; RGK1-UP; J2M1-UP; 10S1-UP; 11S1-UP; 80S1-UP)
772B (S/N: 64W1-UP)
772D (S/N: 5HR1-UP)

772G (S/N: KE31-UP; TWB1-UP; RME1-UP; RMH1-UP; LTS1-UP; KEX1-UP; LTX1-
UP)
773 (S/N: 63G1-UP)
773B (S/N: 5SC1-UP; 63W1-UP)
773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP; 7FZ1-UP)

773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)
773F (S/N: EED1-UP; EXD1-UP)

773GC (S/N: RJZ1-UP)
776 (S/N: 14H1-UP; 14W1-UP)

776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)

776D (S/N: 5ER1-UP; AFS1-UP)
777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP; 3NF1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: DCB1-UP; AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP; 6XZ1-
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)
779 (S/N: 45H1-UP)
783B (S/N: 8YM1-UP)

784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)

785C (S/N: AP21-UP; 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
785G (S/N: SH21-UP; MS41-UP; TRG1-UP; RTL1-UP; WHS1-UP)
786 (S/N: 01A1-UP; 80A1-UP; 81A1-UP)
787B (S/N: 9TM1-UP)

789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SP21-UP; SPD1-UP; SHH1-UP; TWP1-UP)

789G (S/N: TR21-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)

793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)
796 (S/N: HRP1-UP; HRY1-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)
798 (S/N: ST71-UP)
Paving Compactor
All
Pipelayer
All
Quarry Truck
771C (S/N: 3BJ1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
773G (S/N: G731-UP; G771-UP; MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)

775B (S/N: 7XJ1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
775F (S/N: EYG1-UP; DLS1-UP)
775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)
Road Reclaimer/Soil Stabilizer
All
Soil Compactor
815K (S/N: SL91-UP; T1Y1-UP)
825K (S/N: 2L91-UP; 2T91-UP)
Telehandler
All
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Underground Articulated Truck
All
Wheel Dozer
All
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All
Introduction
Revision Summary of Changes in SEBF8048
Added new serial number prefixes for New Product Introduction (NPI).
Tables arranged in alpha numeric sequence.
Table 6 divided in to 8 tables. Each table is now with the corresponding
illustration.
21 Added Illustration 34 to the "Metal Spray Method to Repair Seal Surfaces"
section.
Added 8 part numbers.
The 110-2141 Yoke dimension "B" has been updated with the correct
dimension.
Added 4 part numbers.
20
Added content from SEBF2152, "Thermal Spray Procedures for
Transmission and Torque Converter Yokes".
19
Updated copyright date to 2018.
18 Added 4 part numbers.
17 Added 16 part numbers.
Table 1
© 2019 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).
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.
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.
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
(insert component name). 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.
Note: Illustrations in this guideline may appear different from some of the
components. While the illustrations are typical, the dimensions are actual. All the
dimensions that are listed are dimensions for manufacturing and assembling a
new machine.
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
PERJ1017 Special Publication"Dealer Service Tools Catalog"
SEBF8187 Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures"
Reuse and Salvage Guidelines
SEBF9236 "Fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for reconditioning Components"
(1)

SEBF9238
"Fundamentals of Arc Spray for reconditioning Components" (1)
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
information which pertain to the components being repaired.
Tooling and Equipment
NOTICE
Failure to follow the recommended procedure or the specified
tooling that is required for the procedure could result in damage
to components.
To avoid component damage, follow the recommended

procedure using the recommended tools.
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.
Required Tooling and Equipment
Part
Description Designation
Number
Personal Protective Equipment
— (1) Personal Protection
(PPE)
1S-0258 Plastic Hammer Assembly General Tooling
1U-7262 Telescoping Magnet General Tooling
Automatic Tape Measure (1-inch X
Measurement
1U-9367 26- ft)
Checks
25.4- mm x 8- m
Caliper Profile
4S-9405
304.8 mm (12.00 inch) Measurement
Tool
Measurement
5P-3920 Rule
Checks
304.8 mm (12.00 inch)
Feeler Gauge Thickness
8H-8581 0.038 - 0.635 mm Measurement
(0.0015 - 0.0250 inch) Checks
Tools (Micrometer) Internal
385-9422 Internal Measurement
(2 - 24 inch) Checks
Tool (Ruler) Measurement
386-3364
1,000.0 mm (39.37 inch) Checks
Micrometers External
431-4150 External Measurement
0 - 25 mm (0 - 1 inch) Checks
Instrument Group
Micrometer, Inside
473-8688 2.00 - 12.00 inch Internal
or Measurement
473-8689 Instrument Group Checks
Micrometer, Inside
50 - 300 mm
Instrument Group External
473-8690 Micrometer, Outside Measurement
0.00 - 4.00 inch Checks
Instrument Group External
473-8691 Micrometer, Outside Measurement
2.00 - 6.00 inch Checks
Instrument Group
External
Micrometer, Outside - Digital
473-8692 Measurement
152.4 - 304.8 mm
Checks
(6.00 - 12.00 inch)
Instrument Group
Micrometer, Inside
474-3709 (8.00 - 32.00 inch) Internal
or Measurement
474-3710 Instrument Group Checks
Micrometer, Inside
200 - 800 mm
— GO/NO-GO Thread Gauge Set,

Metric Threaded Hole
and /or
Inspection
— GO/NO-GO Thread Gauge Set, SAE
Threaded Hole
—(1) Plastic Plug Assortment
Protection
Threaded Hole
— (1) Tap and Die Set
/ Restore
Surface
1U-5516 Disc (Coarse) Preparation
/ De-burring
Surface
1U-5518 Threaded Shaft Preparation
/ De-burring
Surface
1U-5519 Holder (Disc Pad) Preparation
/ De-burring
Wheel Surface
4C-8514 (2 x 1 inch) Preparation
(60 Grit) / De-burring
Grinding Wheel (F-Grade) Surface
4C-8515 (2 x 1 inch) Preparation
(120 Grit) / De-burring
Surface
4C-8521 Wheel Adapter Preparation
/ De-burring
Surface
Die Grinder
222-3076 Preparation
(Right Angle)
/ De-burring
Brush Surface
254-5319 76.2 x 50.8 mm Preparation
(3.00 x 2.00 inch) / De-burring
9U-7377 (2) Metal Marking Pen Parts Marking
1U-9918 Brush General Cleaning
Surface Reconditioning Pad (180
8T-7765 General Cleaning
Grit)
162-5791 Towel General Cleaning
— Paint Primer Sleeve Installation
6V-6193 Diagonal Cutter Sleeve Installation
— Compound (Retaining) Sleeve Installation
213-1983 Pliers Sleeve Installation
Tool Group
8T-5096 Run-Out Checks
Dial Indicator
Total Indicator Reading (TIR)
7H-1940 Universal Attachment (90°)
checks
Total Indicator Reading (TIR)
9S-8903 Indicator Contact Point
checks
Comparison Gauge (Surface Surface Texture
9A-1593
Texture) Tester
Tool Surface Texture
453-5376
Specimen Tester
Indicator Surface Texture
448-3698
(Profilometer) Tester
Seal Pick Gear/ Shaft
5P-7414
Kit Step Inspection
Visual Surface
8S-2257 Magnifying Glass
Inspection (VT)
Visual Surface
9U-6182 Mirror (Telescoping)
Inspection (VT)
Visual Surface
9U-7231 Flashing Lights Conversion Kit
Inspection (VT)
Visual Surface
4C-9442 Light
Inspection (VT)
Visual Surface
— (1) Bright Incandescent Light
Inspection (VT)
Visual Surface
— Reflective Surface for Inspection
Inspection (VT)
Crack/
Microscope (40-Power)
262-8390 Measurement
Pocket
Inspection
Liquid Penetrant
288-4209 Paper Towel
Testing (PT)
General Cleaning/
Brush
1U-9915 Liquid Penetrant
Curved Handle Wire
Testing (PT)
Liquid Penetrant
— Developer
Testing (PT)
Liquid Penetrant
— Penetrating Oil
Testing (PT)
General Cleaning/
— Solvent Cleaner Liquid Penetrant
Testing (PT)
Dry Magnetic
Crack Detection Kit (Magnetic
263-7184 Particle Testing
Particle)
(MPT)
Dry Magnetic
— Paint Pen Particle Testing
(MPT)
Wet Magnetic
Lamp Group
459-0184 Particle Testing
Ultraviolet
(MPT)
Table 3
(1)
Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment
(2) (PPE) part numbers suitable by geographic location and local safety standards.
Available in the United States only.
Prepare the Area for Inspection
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.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure.

When using pressure air, wear a protective face shield and
protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa
(30 psi) for cleaning purposes.
Typical burr removal Tooling.
(A) Die Grinder, Right Angle
(B) Wheel Grinder, Group
(C) Conditioning Discs, Disc pad Holder, and Threaded Shaft
(D) Flapper Wheel
Clean all surfaces for inspection before you inspect the part. Make sure that you
remove all debris, paint, and oil.
When you move parts that require cleaning, always use a proper lifting device. This
device must protect the part from damage. For the safety of the operator, all lifting
devices must be inspected before use.
During cleaning, do not damage machined surfaces.
Use pressurized air to dry parts.
If component cannot be inspected immediately after cleaning, put hydraulic oil on all
machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean
container.
Use appropriate thread taps to chase all threaded holes.
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.
NOTICE
Do not use numbering stamp punches to mark internal
components. The impact from striking the stamp will cause an
abnormal stress riser. The added stress riser may cause
premature part failure.
DO NOT use numbering stamp punches to mark internal components.
The procedure for marking components is a Cat standard. This code is helpful when the
machine is sold into a different territory after the first rebuild. During an overhaul, the
previous code of a part should never be removed.
Example 1
Typical Example
Illustration 5 shows code (1-15). The first number (1) indicates that the gear had been
rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear
at the time of rebuild.
Example 2
Typical Example
Illustration 6 shows code (1-12) and code (2-10). Code (2-10) represents the information
from the second rebuild. The first number (2) indicates that the gear had been rebuilt
twice. The second number (10) indicates that 10,000 hours accumulated on the gear
between the first and second rebuild.
Note: Add the first and second rebuild hours to obtain the total number of hours for the
gear in Illustration 6. In this example, the gear has a total of 22,000 hours.
Example 3
Typical Example
(A) Mark the planet pin on either end.
Parts Reusability
Yoke face
(1) Fretting
(2) Slot
Yoke face (close view)
(1) Fretting
Transmission and differential yokes can be damaged by the fretting of the yoke face
during normal operation. Illustration 8 and Illustration 9 show typical examples of fretting.
After machining the face of the yoke flat, OK TO USE THIS PART AGAIN.
If there is heavy fretting in the slot area, DO NOT USE THIS PART AGAIN.
The darker line of wear around the center of the shaft is caused by the lip-type seal.
(3) Wear groove
Transmission and differential yokes can also be damaged by wear of the yoke shaft. The
lip-type seals cause wear on the seal contact area of the shaft. “Wear” is defined as
being able to feel a step in the seal contact area, as shown in Illustration 10.
If shaft damage is found, Caterpillar recommends machining the yoke face first, if
necessary. Then repair the shaft damage.
Procedure to Machine Yoke Faces
1. Clean and inspect the yoke thoroughly. If there is any wear of the yoke shaft, refer
to the "Repairing Shaft Seal Wear" section.
(A) Diameter
2. Carefully install the yoke in a lathe to prevent damage to the seal surface. Use
diameter (A) as the surface for the chuck jaws.
Yoke installed in a lathe chuck
3. Use a dial indicator equipped with a 7H-1940 Universal Attachment (90°) to check
the Total Indicator Reading (TIR) of an area of the yoke face that is not worn. Refer
to Illustration 12. The maximum TIR for the yoke face is 0.13 mm (0.005 inch).
Cutting tools and holder necessary to machine yoke faces.
4. Use a triangular type carbide/ceramic cutting tool to machine the yoke face, as
shown in Illustration 13. Turn large pieces approximately 50 rpm and smaller pieces
between 150 and 180 rpm. Use a feed-rate of between
0.13 mm/rev and 0.36 mm/rev (0.005 inches/rev and 0.014 inches/rev) for both
sizes.
5. As the yoke face is machined, make sure that all nicks, pits, and debris are
removed.
If more than 0.51 mm (0.020 inch) of material is removed, then DO NOT USE THIS
PART AGAIN.
Machined yoke face.
6. Feel the surface texture with your finger. If the machining grooves cannot be felt,
the surface texture is acceptable. If the machining grooves can be felt, use a
surface texture analyzer to determine if the surface texture is acceptable. The
maximum allowable surface texture is 6.35 µm (250 µinch) or smoother. Refer to
Illustration 14.
NOTICE
To reduce fretting in the future, be sure to remove any paint on
the contact surfaces of both the yoke and any part fastened to
the yoke before installing the yoke on the transmission or
differential. Also, tighten all bolts to the correct torque.
7. To prevent corrosion, put a thin layer of rust inhibitor or oil on the yoke.
Note: Ensure that the oil or rust inhibitor is removed prior to installation.
Repairing Shaft Seal Wear

Lip-type seals can cause a groove to wear in the contact surface of the mating part. Many
times this part could be used again except for the groove wear. Wear sleeves are now
available to install over the groove to give a new seal surface to the worn part. The wear
sleeve will allow reuse of the worn part and allow the use of the original seal part number.
This guideline gives the part numbers of the wear sleeves, the sleeve drivers (installation
tools), and the procedure needed to make the repair. Table 4 gives the part number of the
sleeve to install according to the size of the shaft. Table 5 provides the part number of the
sleeve according to the part number of the yoke or flange being repaired.
Wear Sleeves and Wear Sleeve Drivers
(4) Rolled surface
(5) Driver
(6) Driver
(7) Driver
Driver (6) has rolled surface (4).
There is a specific driver to use for installation of each wear sleeve. The drivers are all
either a type (5), (6), or (7) as shown in Illustration 15. The type (5) and type (7) drivers
have a closed end (shown) and an open end (not shown). These two drivers can be used
in only one way to install a wear sleeve. To use type (6) drivers (open on both ends),
always put the end that has the rolled (round) part (4), next to the sleeve.
Illustration 16 shows a typical wear sleeve. The wear sleeve is made in one piece and
has a wear surface (9) for the seal, and a flange (8). In most applications of the wear
sleeve, the flange will be removed.
Application Chart by Reference to Shaft Size
Sleeve Part Sleeve

Shaft Size
Number Driver
19.81 mm to 19.91 mm
5P-6158 5P-6195
(0.780 inch to 0.784 inch)
22.17 mm to 22.28 mm
5P-6159 5P-6195
(0.873 inch to 0.877 inch)
22.94 mm to 25.04 mm
5P-6160 5P-6196
(0.903 inch to 0.986 inch)
25.35 mm to 25.45 mm
5P-6161 5P-6196
(0.998 inch to 1.002 inch)
26.92 mm to 27.03 mm
5P-6162 5P-6197
(1.060 inch to 1.064 inch)
27.94 mm to 28.04 mm
5P-6163 5P-6197
(1.100 inch to 1.104 inch)
28.52 mm to 28.63 mm
5P-6164 5P-6198
(1.123 inch to 1.127 inch)
29.31 mm to 29.41 mm
5P-6165 5P-6198
(1.154 inch to 1.158 inch)
31.67 mm to 31.83 mm
5P-6166 5P-6198
(1.249 inch to 1.253 inch)
34.85 mm to 35.00 mm
5P-6167(1) 5P-6199
(1.372 inch to 1.378 inch)
34.85 mm to 35.00 mm
5P-6168(1) 5P-6199
(1.372 inch to 1.378 inch)
36.45 mm to 36.60 mm
5P-6169 5P-6200
(1.435 inch to 1.441 inch)
38.02 mm to 38.18 mm
5P-6170 5P-6200
(1.497 inch to 1.503 inch)
41.20 mm to 41.35 mm
5P-6148(2) 5P-6149
(1.622 inch to 1.628 inch)
41.20 mm to 41.35 mm
5P-6171(2) 5P-6149
(1.622 inch to 1.628 inch)
42.80 mm to 42.95 mm
5P-6172 5P-6150
(1.685 inch to 1.691 inch)
44.37 mm to 44.53 mm
5P-6173 5P-6150
(1.747 inch to 1.753 inch)
47.55 mm to 47.70 mm
4C-6257 5P-6151
(1.872 inch to 1.878 inch)
48.49 mm to 48.64 mm
5P-6174 5P-6151
(1.909 inch to 1.915 inch)
49.12 mm to 49.28 mm
5P-6175 5P-6151
(1.934 inch to 1.940 inch)
49.91 mm to 50.06 mm
4C-6258 5P-6151
(1.965 inch to 1.971 inch)
53.90 mm to 54.05 mm
5P-6176 5P-6201
(2.122 inch to 2.128 inch)
60.25 mm to 60.40 mm
5P-6177 5P-6201
(2.372 inch to 2.378 inch)
61.85 mm to 62.00 mm
5P-6178 5P-6201
(2.435 inch to 2.445 inch)
63.47 mm to 63.63 mm
5P-6179 5P-6201
(2.499 inch to 2.505 inch)
65.00 mm to 65.15 mm
5P-6180 5P-6202
(2.559 inch to 2.565 inch)
66.60 mm to 66.75 mm
5P-6181 5P-6202
(2.622 inch to 2.628 inch)
69.77 mm to 69.93 mm
5P-6182 5P-6203
(2.747 inch to 2.753 inch)
72.95 mm to 73.10 mm
5P-6183 5P-6204
(2.872 inch to 2.878 inch)
76.12 mm to 76.28 mm
5P-6184 5P-6204
(2.997 inch to 3.003 inch)
79.30 mm to 79.45 mm
5P-6185 5P-6205
(3.122 inch to 3.128 inch)
82.47 mm to 82.63 mm
5P-6186 5P-6206
(3.247 inch to 3.253 inch)
88.93 mm to 89.08 mm
5P-6187 5P-6207
(3.501 inch to 3.507 inch)
90.42 mm to 90.58 mm
4C-6259 5P-6208
(3.560 inch to 3.566 inch)
91.87 mm to 92.02 mm
5P-6188 5P-6208
(3.617 inch to 3.623 inch)
93.60 mm to 93.75 mm
5P-6189 5P-6208
(3.685 inch to 3.691 inch)
95.15 mm to 95.30 mm
4C-6260 5P-6208
(3.746 inch to 3.752 inch)
101.50 mm to 101.70 mm
5P-6190 5P-6209
(3.996 inch to 4.004 inch)
107.90 mm to 108.10 mm
4C-6261 4C-6742
(4.248 inch to 4.256 inch)
114.20 mm to 114.40 mm
5P-6191 5P-6210
(4.496 inch to 4.504 inch)
120.55 mm to 120.75 mm
4C-6262 4C-6743
(4.746 inch to 4.754 inch)
123.72 mm to 123.93 mm
5P-6192 5P-6211
(4.871 inch to 4.879 inch)
126.95 mm to 127.15 mm
4C-6263 4C-6744
(4.998 inch to 5.006 inch)
157.43 mm to 157.68 mm
5P-6193 5P-6212
(6.198 inch to 6.208 inch)
189.08 mm to 189.33 mm
5P-6194 5P-6213
(7.444 inch to 7.454 inch)
Table 4
(1)
Two wear sleeves available: Width of 5P-6167 Wear Sleeve is 15.88 mm (0.625 inch) and 5P-6168 Wear
(2) Sleeve is 11.13 mm (0.438 inch).
Two wear sleeves available: Width of 5P-6148 Wear Sleeve is 11.13 mm (0.438 inch) and 5P-6171 Wear
Sleeve is 17.48 mm (0.688 inch).
Note: If a wear sleeve is not available, refer to the "Metal Spray Method to Repair Seal
Surfaces" section.
Seal Surface Repair Sleeves

(by reference to yoke/flange part number)
Sleeve Part
Yoke Assembly Yoke/Flange
Number(1)
— 1J-0768 5P-6180
— 1P-0318 5P-6184
— 1P-6683 5P-6182
— 1P-6688 5P-6181
1P-7522 1P-7521 5P-6184
— 1S-1532 5P-6184
— 1S-8541 5P-6192
— 1T-1386 5P-6184
— 1T-1565 4C-6261
8P-0514 1V-8565 5P-6190
— 2D-2618 5P-6181
— 2D-9203 4C-6260
— 2K-3632 5P-6183
— 2K-5129 5P-6184
— 2K-5977 5P-6184
2P-3633 2P-3632 5P-6182
— 2P-4392 5P-6184
4C-1677, 193-4589 2P-9155, 193-7146 5P-6184
— 2R-0975 5P-6190
2S-3180 2S-3179 4C-6260
104-6497 2U-9436 5P-6190
— 2V-5418 4C-6263
— 2V-7058 5P-6185
— 2V-7083 5P-6185
— 2V-7170 5P-6190
— 3J-5312 5P-6177
— 3P-3205 5P-6182
— 3P-3207 5P-6181
— 3P-3208 5P-6177
— 3P-3450 5P-6185
— 3P-3452 5P-6184
— 3P-3504, 173-0713 5P-6190
— 3P-5672 5P-6184
323-2169 3P-8143 5P-6178
— 3S-7921 5P-6190
— 3S-9879 5P-6190
— 3S-9911 5P-6190
— 3T-0017 4C-6260
3T-2256 3T-0018 5P-6185
— 3T-3966 5P-6184
— 3T-4953 5P-6181
3T-4955 3T-4954 5P-6181
3T-5430 3T-5429 5P-6185
3T-5432 3T-5431 5P-6185
— 3T-8304 5P-6172
— 3T-8903 5P-6178
— 3T-9287 5P-6178
— 3W-5606 —
— 4D-1939 4C-6260
— 4D-7934 5P-6191
— 4H-3648 5P-6179
— 4H-6931 5P-6190
— 4H-8475 5P-6180
— 4K-5086 5P-6182
— 4K-7556 5P-6185
— 4M-3110 5P-6185
— 4U-1688 5P-6184
— 4U-6482 5P-6184
— 4U-6981 5P-6184
— 5B-8200 4C-6260
— 5D-6029 5P-6180
— 5D-6133 5P-6186
— 5K-0228 5P-6185
— 5K-4386 5P-6185
— 5M-7199 5P-6180
— 5M-7342 5P-6181
— 5S-0951 5P-6184
— 5S-0952 5P-6184
— 5U-4371 5P-6184
— 5U-4372 5P-6185
— 5V-2539 5P-6185
— 5V-3733 5P-6185
— 5V-6325 5P-6185
— 5V-6327 —
5V-6328 5V-6329 5P-6185
— 5V-8975 5P-6185
7I-4187 5V-7581 5P-6183
6G-8197 6G-8198 5P-6183
6I-8053 6I-8052 5P-6184
— 6K-4363 5P-6185
— 6K-4598 5P-6184
— 6K-4600 5P-6184
— 6K-5899 5P-6185
— 6K-7355 5P-6185
— 6K-7357 5P-6185
— 6P-8623 5P-6177
— 6P-8628 5P-6184
— 6S-0286 5P-6190
— 6S-3158 5P-6183
— 6S-5978 5P-6183
— 6S-6043 5P-6182
7T-3370 6T-8409 5P-6185
— 6T-9231 5P-6187
— 6T-9233 5P-6187
— 6T-9576 5P-6182
107-5610 6W-4281 4C-6261
6Y-6638 6Y-6630 —
6Y-6637 6Y-6631 —
6Y-6636 6Y-6633 4C-6263
6Y-8137 6Y-7138 4C-6263
— 6Y-8158 5P-6182
— 6Y-8972 5P-6185
— 6Y-9644 5P-6176
7G-1139 7G-1161 —
— 7G-3495 5P-6180
— 7G-6896 —
159-1847 7I-3893 5P-6184
— 7I-4186 5P-6184
— 7K-0395 5P-6185
— 7K-0438 5P-6185
— 7K-0767 5P-6190
3K-9917, 7K-1261 3K-9663, 7K-1261 5P-6190
— 7K-7616 5P-6187
— 7M-5933 5P-6184
— 7T-2821 5P-6185
— 7T-2822 5P-6185
— 7T-2823 5P-6185
— 7T-3064 5P-6185
7T-3115, 312-6539 7T-3115, 312-6539 4C-6261
7T-4007 7T-4006 5P-6185
— 7T-5035 5P-6184
— 7T-5646 4C-6261
— 7U-3262 5P-6187
— 7V-2150 5P-6190
7V-2151 7V-2152 5P-6190
— 7V-2154 5P-6190
— 7V-4074 5P-6185
— 7V-4075 5P-6185
— 7V-4084 5P-6186
8D-1948 8D-0526 5P-6183
235-2642 8E-0367, 235-2643 —
8E-1774 8E-1775 5P-6190
— 8E-1873 4C-6261
— 8E-2992 4C-6263
— 8E-3679 5P-6190
8E-4616 8E-4586 5P-6184
8E-7087 8E-5910 5P-6190
8E-9487 8E-9466 5P-6190
— 8M-8161 5P-6190
— 8M-8628 5P-6177
9G-3542 8P-1719 5P-6185
— 8P-1880 4C-6261
— 8P-4455 —
— 8P-4543 —
— 8P-5653 —
— 8P-6083 5P-6190
— 8P-7351 5P-6190
— 8P-7456 5P-6181
101-7689 8P-8559 5P-6185
8P-8843 8P-8844 5P-6190
— 8R-8516 4C-6263
— 8S-3497 5P-6182
— 8S-3554 5P-6185
— 8S-6259 5P-6182
— 8S-6263 5P-6177
— 8S-6370 5P-6190
100-6769 8V-7320 5P-6182
— 8W-1591 5P-6184
8W-1592 8W-1592 5P-6177
— 8Y-0803 5P-6180
— 8Y-0806 5P-6182
— 8Y-0808 5P-6180
— 9C-1394 5P-6185
— 9C-1395 5P-6185
— 9C-3525 5P-6183
— 9C-4080 5P-6185
— 9C-7415 5P-6184
— 9G-0401 5P-6177
— 9G-0925 5P-6176
— 9G-5844 5P-6184
— 9G-9002 5P-6181
— 9K-7915 5P-6184
— 9K-7916 5P-6184
— 9M-2062 4C-6263
— 9M-2514 4C-6260
— 9M-6844 5P-6177
— 9P-0071 5P-6190
9G-1930 9P-1250 5P-6190
— 9P-9244 5P-6187
— 9R-4315 5P-6181
— 9S-5263 5P-6177
— 9S-8147 5P-6180
— 9S-9880 4C-6260
9W-7704 9W-7703 5P-6181
9W-7702 9W-7705 5P-6181
— 034-8552 4C-6257
— 038-2736 4C-6257
— 068-2949 5P-6182
— 068-4797 5P-6176
— 068-9565 5P-6182
— 108-5732 5P-6182
— 108-5735 5P-6182
— 108-6954 4C-6257
108-8296 108-8297 5P-6178
110-9311 110-9310 5P-6187
— 112-0782 5P-6178
— 112-5460 4C-6263
112-4782, 163-1106, 113-4633, 163-1105,
5P-6190
162-9969 162-9967
— 115-1326 5P-6178
121-3173 121-3172 5P-6184
124-9302 124-9301 4C-6263
117-4465 125-8800 5P-6184
— 134-3032 5P-6177
134-4077 134-4077 4C-6261
— 137-2417 4C-6261
— 142-1280 5P-6187
— 143-1736 —
148-9319 148-9318 5P-6184
153-1229 149-3973 4C-6263
— 155-5602 5P-6177
— 156-1150 5P-6177
— 156-1151 5P-6178
158-0424 158-0425 —
— 160-1400 5P-6184
— 171-6803 4C-6263
193-4589 193-7146 5P-6184
199-7967 199-7966 4C-6263
203-2759 203-2760 5P-6184
225-0086 224-9314 4C-6262
— 250-3221 5P-6185
255-0777 256-3657 —
271-7121 271-7122 5P-6179
271-8522 271-8522 5P-6179
271-8523 271-8523 5P-6179
279-2540 279-2547 —
— 287-4002 4C-6742
315-6193 322-7313 4C-6261
122-6787 324-1357 4C-6257
— 331-8520 5P-6180
334-7506 334-7971 5P-6174
348-7762 348-7761 None
357-0596 357-0596 5P-6182
366-5616 357-0597 5P-6182
366-5615 357-0598 5P-6182
358-3824 358-3825 4C-6261
388-8448 362-7687 4C-6257
— 364-4406 4C-6259
365-1297 364-4407 4C-6259
— 378-2791 5P-6181
383-7979 383-8019 5P-6173
260-3964 387-7687 5P-6184
430-7997 394-9495 5P-6174
441-9224 441-9225 5P-6185
— 437-5514 4C-6261
— 476-8753 —
486-2947 486-2946 5P-6184
483-1058 501-9091 5P-6184
Table 5
(1)
Refer to Table 4 for the corresponding sleeve driver.
Wear Sleeve Installation

Wear surface of seal with wear groove (3)
1. Carefully inspect the shaft surface for seal wear. Wear groove (3) shows typical
wear caused by a lip-type seal.
Cleaning method that can be used on yokes, shafts, and flanges.
2. Clean the wear surface thoroughly with a 180 grit or finer emery cloth. Use a file to
remove any nicks or burrs (deep grooves or notches).
Wear sleeve installation
(3) Wear groove
(8) Flange
(9) Wear surface
(10) Wear sleeve
(11) Mark
3. Hold wear sleeve (10) in the position shown in Illustration 19, so that the center of
new wear surface (9) is over wear groove (3). Then, make a mark (11) that is even
with the back of flange (8) on wear sleeve (10). If the flange (8) will be against a
shoulder after the sleeve is installed, mark (11) is not needed. Refer to Step 8.
Note: If there is more than one wear groove, make sure that all wear grooves will
be covered an even amount.
Shaft with wear groove
(3) Wear groove
4. If groove (3) is a deep groove, fill with a powdered metal epoxy and install the wear
sleeve before the epoxy becomes hard. If the powdered metal is not needed, put
Paint Primer on the area around groove (3). Put a small amount of 9S-3265
Compound on the area around groove (3) and inside of the new wear sleeve.
Install wear sleeve
(8) Flange
(10) Wear sleeve
(11) Mark
5. Put wear sleeve (10) in position so flange (8) goes on first, as shown in Illustration
21. Be sure that the wear sleeve is kept straight as during installation. Use the
correct sleeve driver and a press to install the wear sleeve in the correct position.
Drive wear sleeve onto shaft with a press or a soft hammer.
6. If a press is not available, use a soft hammer with the sleeve driver to install the
wear sleeve, as shown in Illustration 22.
Sleeve driver (6) with roller part (4)
7. If a type (6) sleeve driver is used (refer to "Wear Sleeves and Wear Sleeve
Drivers"), be sure to put the rolled (round) part (4) next to the sleeve.
Shaft with chamfer
(8) Flange
(12) Chamfer
8. If there is a chamfer (12) on the original wear surface for the seal, install the wear
sleeve far enough so that the end of the wear sleeve is beyond the chamfer, as
shown in Illustration 24. If flange (8) of the wear sleeve is against a shoulder, do not
remove. If flange (8) is not against a shoulder, it must be removed. Refer to Step 9.
Remove flange
(8) Flange
(13) Diagonal pliers
(14) Pre-cut line
9. If flange (8) of the wear sleeve is not against a shoulder, and must be removed, use
diagonal pliers (13) to cut flange (8) up to pre-cut line (14).
Flange removal
(8) Flange
(15) Pliers
10. Use straight pliers (15) to bend and remove flange (8).
Metal Spray Method to Repair Seal Surfaces

Metal spray is an acceptable method of restoring a surface to the original size. Refer to
section "Thermal Spray Procedure". Also, consult the manufacturer of the metal spray
equipment for powder recommendations, machine settings, and application procedures.
Each step in the procedure is critical in achieving the desired coating bond and surface
texture.
Note: Sometimes, a yoke with seal lip damage can be reused without any salvage
operations by installing the seal at a different position.
Acceptable surface texture on the shaft seal area must be within 0.25 mm and 0.50 mm
(0.010 inch and 0.020 inch).
Plunge grinding is the grinding technique that should be used on the shaft sealing
surface. This eliminates the possibility of a leak path that can be created if the traverse
grinding method is used.
Typical example of a Yoke.
Note: (C*) is when the other is not given.
Refer to Illustration 27 for dimensions listed in Table 6.
Transmission and Differential Yokes
Part Yoke Dimension D

Dimension A Dimension B Dimension C
Number Number Radius
36.60 ± 0.08 mm 76.20 ± 0.03 mm 3.00 ± 0.50 mm 1.50 ± 0.50 mm
1P-7522 1P-7521
(1.44 ± 0.003 inch) (3.00± 0.001 inch) (0.12 ± 0.02 inch) (0.06 ± 0.02 inch)
38.10 ± 0.25 mm 90.47 ± 0.08 mm 1.49 ± 0.25 mm 1.50 ± 0.50 mm
1T-0364 1T-0364
(1.50 ± 0.01 inch) (3.56 ± 0.003 inch) (0.06 ± 0.01 inch) (0.06 ± 0.02 inch)
38.10 ± 0.25 mm 90.47 ± 0.08 mm 1.49 ± 0.25 mm 1.50 ± 0.5 mm
1T-0365 1T-0365
22.86 ± 0.25 mm 76.20 ± 0.03 mm 3.00 ± 0.50 mm 1.50 ± 0.50 mm
1T-1386 1T-1386
41.15 ± 0.25 mm 107.95 ± 0.13 mm 1.50 ± 0.25 mm 1.60 ± 0.40 mm
1T-1565 1T-1565
29.46 ± 0.08 mm 76.20 ± 0.03 mm 2.40 ± 0.50 mm 1.50 ± 0.50 mm
2P-4392 2P-4392
35.00 ± 0.25 mm 95.25 ± 0.05 mm 1.50 ± 0.25 mm 0.80 ± 0.25 mm
2S-3180 2S-3179
50.80 ± 0.20 mm 127.00 ± 0.10 mm 3.00 ± 0.25 mm 3.30 ± 0.25 mm
2V-5418 2V-5418
50.80 ± 0.50 mm 127.00 ± 0.10 mm 4.80 ± 0.050 mm 4.80 ± 0.050 mm
2V-5893 2V-5893
63.50 ± 0.50 mm 127.00 ± 0.10 mm 4.80 ± 0.50 mm
4E-2402 4E-2402 4.04 mm (0.16 inch)
(2.50 ± 0.02 inch) (5.00 ± 0.004 inch) (0.19 ± 0.02 inch)
63.50 ± 0.50 mm 127.00 ± 0.10 mm 4.80 ± 0.50 mm
4E-3194 4E-3194 4.04 mm (0.16 inch)
(2.50 ± 0.02 inch) (5.00 ± 0.004 inch) (0.19 ± 0.02 inch)
59.7 ± 0.5 mm 101.60 ± 0.08 mm 4.80 ± 0.50 mm 6.4 ± 0.5 mm
4E-3751 4E-3751
34.52 ± 0.25 mm 95.25 ± 0.05 mm 2.10 ± 0.25 mm 1.19 ± 0.25 mm
5D-0534 5D-0534
30.23 ± 0.25 mm 101.60 ± 0.08 mm 5.30 ± 0.50 mm .80 ± 0.20 mm
6P-2923 173-0713
29.46 ± 0.25 mm 76.20 ± 0.08 mm 2.39 ± 0.25 mm 1.60 ± 0.40 mm
6P-4232 8P-6189
33.00 ± 0.50 mm 101.60 ± 0.08 mm 2.50 ± 0.50 mm 2.50 ± 0.50 mm
6Y-1415 6Y-1415
50.75 ± 0.25 mm 127.00 ± 0.10 mm 3.00 ± 0.25 mm 3.30 ± 0.25 mm
6Y-6636 6Y-6633
35.00 ± 0.50 mm 127.00 ± 0.10 mm 3.05 ± 0.25 mm 3.00 ± 0.50 mm
6Y-8137 6Y-7138
86.09 ± 0.13 mm 142.888 ± 0.013 mm 1.20 ± 0.30 mm
7G-1139 7G-1161 3.50 mm (0.14 inch)
(3.39 ± 0.005 inch) (5.6255 ± 0.0005 inch) (0.05 ± 0.01 inch)
7T-3115 7T-3115 44.00 ± 0.50 mm 107.95 ± 0.13 mm 1.70 ± 0.50 mm 1.60 ± 0.40 mm
312-6539 312-6539 (1.73 ± 0.02 inch) (4.25 ± 0.005 inch) (0.07 ± 0.02 inch) (0.06 ± 0.02 inch)
46.50 ± 0.08 mm 76.20 ± 0.03 mm 3.00 ± 0.50 mm 1.60 ± 0.50 mm
8E-4616 8E-4586
8E-7087 8E-5910 49.80 ± 0.25 mm 101.60 ± 0.08 mm 4.80 ± 0.50 mm 6.4 ± 0.5 mm
85.09 ± 0.13 mm 136.54 ± 0.01 mm 1.50 ± 0.25 mm
8P-5653 8P-5653 3.05 mm (0.12 inch)
(3.35 ± 0.005 inch) (5.38 ± 0.00039 inch) (0.06 ± 0.01 inch)
64.3 ± 0.5 mm 79.45 ± 0.05 mm 3.00 ± 0.5 mm 3.00 ± 0.5 mm
8W-1592 8W-1592
41.50 ± 0.25 mm 82.55 ± 0.08 mm 3.00 ± 0.5 mm 2.00 ± 0.5 mm
108-6954 108-6954
77.2 ± 0.5 mm 76.20 ± 0.08 mm 5.1 ± 0.5 mm 4.00 ± 0.5 mm
112-0782 112-0782
50.80 ± 0.20 mm 127.00 ± 0.10 mm 4.8 ± 0.5 mm
112-5460 112-5460 —
(2.00 ± 0.008 inch) (5.00 ± 0.004 inch) (0.189 ± 0.02 inch)
35.00 ± 0.25 mm 76.20 ± 0.08 mm 2.50 ± 0.50 mm 1.60 ± 0.40 mm
121-3173 121-3172
124-9302, 124-9301, 50.80 ± 0.50 mm 127.00 ± 0.10 mm 3.05 ± 0.25 mm 3.00 ± 0.50 mm
50.80 ± 0.50 mm 127.00 ± 0.10 mm 4.80 ± 0.50 mm
132-0347 132-0347 3.06 mm (0.12 inch)
(2.00 ± 0.02 inch) (5.00 ± 0.004 inch) (0.19 ± 0.02 inch)
74.7 ± 0.5 mm 101.6 ± 0.08 mm 5.00 ± 0.5 mm .8 ± 0.5 mm
134-3032 134-3032
32.7 ± 0.5 mm 107.95 ± 0.1 mm 2.975 ± 0.1 mm 1.6 ± 0.4 mm
137-2417 137-2417
50.80 ± 0.20 mm 127.00 ± 0.10 mm 3.00 ± 0.25 mm 3.30 ± 0.25 mm
153-1229 149-3973
77.2 ± 0.5 mm 76.2 ± 0.08 mm 5.00 ± 0.5 mm 4.00 ± 0.5 mm
155-5602 155-5602
88.8 ± 0.5 mm 101.6 ± 0.08 mm 5.00 ± 0.5 mm .8 ± 0.5 mm
156-1150 156-1150
77.2 ± 0.5 mm 76.20 ± 0.08 mm 5.1 ± 0.5 mm
156-1151 156-1151 —
(3.04 ± 0.02 inch) (3.00 ± 0.003 inch) (0.20 ± 0.02 inch)
60.8 ± 0.5 mm 127.00 ± 0.10 mm 4.8 ± 0.5 mm
171-6803 171-6803 —
(2.3937 ± 0.02 inch) (5.00 ± 0.004 inch) (0.189 ± 0.02 inch)
63.50 ± 0.50 mm 127.00 ± 0.10 mm 3.00 ± 0.50 mm 6.00 ± 0.50 mm
172-6103 171-3943
59.7 ± 0.5 mm 101.60 ± 0.08 mm 4.80 ± 0.50 mm 6.4 ± 0.5 mm
173-5850 173-5850
59.7 ± 0.5 mm 101.60 ± 0.08 mm 4.80 ± 0.50 mm 6.4 ± 0.5 mm
176-7289 176-7289
32.00 ± 0.76 mm 92.96 ± 0.76 mm 11.53 ± 0.25 mm 1.60 ± 0.40 mm
193-4589 193-7146
58.90 ± 0.5 mm 76.20 ± 0.06 mm 6.4 ± 0.5 mm
203-2759 203-2760 —
(2.32 ± 0.02 inch) (3.00 ± 0.002 inch) (0.25 ± 0.02 inch)
46.5 ± 0.5 mm 76.2 ± 0.06 mm 6.4 ± 0.5 mm
203-2764 203-2765 —
(1.83 ± 0.02 inch) (3.00± 0.002 inch) (0.25 ± 0.02 inch)
33 ± 0.25 mm 115.93 ± 0.03 mm
225-0086 224-9314 2.29 mm (0.09 inch) 0.5 mm (0.02 inch)
(1.30 ± 0.01 inch) (4.56 ± 0.001 inch)
49.25 ± 0.25 mm 76.20 ± 0.08 mm 3.00 ± 0.5 mm 3.00 ± 0.5 mm
260-3964 387-7687
52.7 ± 1.7 mm 97.0 ± 0.08 mm 2.03 ± 0.25 mm 4.00 ± 0.5 mm
271-7121 271-7122
54.0 ± 0.5 mm 92.07 ± 0.08 mm 1.5 ± 0.25 mm
271-8522 271-8522 0.5 mm (0.02 inch)
(2.13 ± 0.02 inch) (3.62 ± 0.003 inch) (0.06 ± 0.01 inch)
58.4 ± 0.5 mm 97.0 ± 0.08 mm 3.00 ± 0.5 mm 4.00 ± 0.5 mm
271-8523 271-8523
33.00 ± 0.25 mm 115.93 ± 0.03 mm
279-2540 279-2547 2.29 mm (0.09 inch) 0.5 mm (0.02 inch)
(1.30 ± 0.01 inch) (4.56 ± 0.001 inch)
15.0 ± 0.25 mm 48.00 + 0.00 - 0.16 mm 2.00 ± 0.25 mm 2.0 ± 0.25 mm
334-7506 334-7971
(0.59 ± 0.010 inch) (1.890 + 0.00 - 0.006 inch) (0.079 ± 0.010 inch) (0.08 ± 0.010 inch)
99.68 ± 0.13 mm 142.888 ± 0.013 mm 1.20 ± 0.30 mm 3.00 ± 0.50 mm
348-7762 348-7761
62.5 ± 0.5 mm 69.85 ± 0.08 mm
357-0596 357-0596 7.7 mm (0.30 inch) —
(2.46 ± 0.02 inch) (2.75 ± 0.003 inch)
58.90 ± 0.5 mm 69.85 ± 0.08 mm 3.00 ± 0.5 mm
366-5615 357-0598 7.7 mm (0.30 inch)
(2.32 ± 0.02 inch) (2.75 ± 0.003 inch) (0.12 ± 0.02 inch)
58.90 ± 0.5 mm 69.85 ± 0.08 mm 3.00 ± 0.5 mm
366-5616 357-0597 7.7 mm (0.30 inch)
(2.32 ± 0.02 inch) (2.75 ± 0.003 inch) (0.12 ± 0.02 inch)
31.80 ± 0.50 mm 3.00 ± 0.5 mm
378-2791 378-2791 66.68 mm (2.63 inch) 3.23 mm (0.13 inch)
(1.25 ± 0.02 inch) (0.12 ± 0.02 inch)
76.2 ± 0.5 mm 6.4 ± 0.5 mm
— 9U-3668 — —
(3.00 ± 0.02 inch) (0.25 ± 0.02 inch)
49.30 ± 0.5 mm 76.20 ± 0.08 mm 3.00 ± 0.5 mm
— 115-1326 0.5 mm (0.02 inch)
(1.9409 ± 0.0197 inch) (3.00 ± 0.003 inch) (0.12 ± 0.02 inch)
33.00 ± 0.25 mm 115.93 ± 0.03 mm
— 142-1736 2.29 mm (0.09 inch) 0.5 mm (0.02 inch)
(1.30 ± 0.01 inch) (4.56 ± 0.001 inch)
50.0 ± 0.25 mm 76.20 ± 0.08 mm 3.2 ± 0.5 mm
— 383-8942 —
(1.97 ± 0.01 inch) (3.00 ± 0.003 inch) (0.13 ± 0.02 inch)
Table 6

39.50 ± 0.25 mm 88.90 ± 0.08 mm 1.50 mm 3.00 ± 0.25 mm
7U-3262 7U-3262
(1.55 ± 0.01 inch) (3.50 ± 0.003 inch) (0.06 inch) (0.12 ± 0.01 inch)
38 ± 0.5 mm 79.38 ± 0.08 mm 1.5 ± 1 mm 3.0 ± 0.5 mm
9C-4080 9C-4080
34.19 ± 0.25 mm 88.9 ± 0.08 mm 3.0 ± 0.08 mm 1.5 ± 0.25 mm
142-1280 142-1280
Table 7

1T-2006 1T-2006 31.80 ± 0.50 mm 3.00 ± 0.250 mm 1.50 ± 0.50 mm
107.95 ± 0.13 mm (4.25 ± 0.01 inch)
158-0426 158-0426 (1.25 ± 0.02 inch) (0.12 ± 0.01 inch) (0.06 ± 0.02 inch)
36.00 ± 0.50 mm 3.00 ± 0.50 mm 1.60 ± 0.20 mm
9G-3542 8P-1719 76.20 ± 0.08 mm (3.00 ± 0.0031 inch)
(1.42 ± 0.02 inch) (0.12 ± 0.02 inch) (0.063 ± 0.008 inch)
41.00 ± 0.50 mm 1.60 ± 0.40 mm 1.60 ± 0.20 mm
101-7689 8P-8559 76.20 ± 0.08 mm (3.00 ± 0.0031 inch)
(1.61 ± 0.02 inch) (0.06 ± 0.02 inch) (0.063 ± 0.008 inch)
37.5 ± 0.5 mm 55.029 ± 0.01 mm 3.00 ± 0.50 mm 2.0 ± 0.5 mm
108-8296 108-8297
108-8854 108-8855 35.00 ± 0.50 mm 3.05 ± 0.25 mm 3.00 ± 0.50 mm
127.00 ± 0.10 mm (5.00 ± 0.004 inch)
194-2221 194-2220 (1.38 ± 0.02 inch) (0.12 ± 0.01 inch) (0.12 ± 0.02 inch)
36.00 ± 0.5 mm 3.00 ± 0.5 mm
117-4465 125-8800 76.20 ± 0.08 mm (3.00 ± 0.003 inch) 0.5 mm (0.02 inch)
(1.42 ± 0.02 inch) (0.12 ± 0.02 inch)
15.00 ± 0.25 mm 47.92 ± 0.02 mm 48.08 ± 0.05 mm 2.00 ± 0.25 mm 2.00 ± 0.5 mm
122-6787 324-1357
(0.59 ± 0.01 inch) (1.89 ± 0.0008 inch 1.89 ± 0.002 inch) (0.08 ± 0.01 inch) (0.08 ± 0.02 inch)
21.00 +1.5 mm 3.00 ± 0.01 mm
219-8828 219-8828 65.00 - 0.074 mm (2.56 - 0.003 inch) 1.2 mm (0.05 inch)
(0.83 + 0.06 inch) (0.12 ± 0.0004 inch)
50.8 ± 0.5 mm 3.00 ± 0.50 mm 1.60 ± 0.20 mm
230-7160 230-7161 76.20 ± 0.08 mm (3.00 ± 0.0031 inch)
(2.00 ± 0.02 inch) (0.12 ± 0.02 inch) (0.063 ± 0.008 inch)
32.0 ± 0.5 mm 4.00 ± 0.5 mm 3.00 ± 0.25 mm
255-0777 256-3657 146.05 ± 0.1 mm (5.750 ± 0.004 inch)
(1.26 ± 0.020 inch) (0.157 ± 0.020 inch) (0.12 ± 0.01 inch)
47.92 ± 0.02 mm 48.08 ± 0.05 mm 2.00 ± 0.5 mm
388-8448 362-7687 15 mm (0.59 inch) 2.00 mm (0.08 inch)
(1.89 ± 0.0008 inch 1.89 ± 0.002 inch) (0.08 ± 0.02 inch)
38.8 ± 0.5 mm
424-0873 424-0874 76.20 ± 0.08 mm (3.00 ± 0.0031 inch) — —
(1.53 ± 0.02 inch)
21.00 +1.5 mm 3.00 ± 0.01 mm
— 216-4464 65.00 - 0.074 mm (2.56 - 0.003 inch) 1.2 mm (0.05 inch)
(0.83 + 0.06 inch) (0.12 ± 0.0004 inch)
Table 8

22.60 ± 0.50 mm 88.90 ± 0.08 mm 1.55 ± 0.25 mm 1.50 ± 0.50 mm
1T-2000 1T-1999
(0.89 ± 0.02 inch) (3.50 ± 0.003 inch) (0.06 ± 0.01inch) (0.06 ± 0.02 inch)
29.20 ± 0.25 mm 107.95 ± 0.13 mm 3.00 ± 0.50 mm .80 ± 0.20 mm
1T-2032 1T-2030
38.10 ± 0.50 mm 101.60 ± 0.08 mm 4.80 ± 0.25 mm 3.00 ± 0.25 mm
2V-7170 2V-7170
72.0 ± 0.5 mm 3.0 ± 0.5 mm 3.0 ± 0.5 mm
3T-8305 3T-8304 —
(2.83 ± 0.02 inch) (0.12 ± 0.02 inch) (0.12 ± 0.02 inch)
38.10 ± 0.50 mm 101.60 ± 0.08 mm 4.80 ± 0.25 mm 0.80 ± 0.25 mm
6W-7385 6W-4759
40.70 ± 0.25 mm 165.10 ± 0.15 mm 5.00 ± 0.25 mm 1.50 ± 0.25 mm
6Y-6637 6Y-6631
(1.60 ± 0.01 inch) (6.50 ± 0.006 inch) (0.20 ± 0.01 inch) (0.06 ± 0.01inch)
38.50 ± 0.25 mm 165.10 ± 0.15 mm 1.50 ± 0.25 mm
6Y-6638 6Y-6630 —
(1.52 ± 0.01 inch) (6.50 ± 0.006 inch) (0.06 ± 0.01inch)
31.15 ± 0.25 mm 101.60 ± 0.08 mm 5.20 ± 0.50 mm .80 ± 0.20 mm
7V-2151 7V-2152
8E-0367 8E-0367 38.00 ± 0.25 mm 107.95 ± 0.1 mm 4.80 ± 0.50 mm 4.04 ± 0.20 mm
8E-4615 4E-2384 49.66 ± 0.25 mm 101.60 ± 0.08 mm 5.00 ± 0.50 mm .80 ± 0.20 mm
44.50 ± 0.50 mm 101.60 ± 0.08 mm 4.80 ± 0.25 mm 3.00 ± 0.25 mm
8P-0514 1V-8565
41.10 ± 0.50 mm 107.95 ± 0.10 mm 2.80 ± 0.50 mm .80 ± 0.50 mm
8P-1880 8P-1880
34.00 ± 0.50 mm 101.60 ± 0.08 mm 3.00 ± 0.50 mm 1.60 ± 0.40 mm
8P-6083 8P-6083
38.10 mm 101.60 ± 0.03 mm 3.00 ± 0.25 mm 3.00 ± 0.08 mm
8S-6370 8S-6370
(1.50 inch) (4.00 ± 0.001 inch) (0.12 ± 0.01 inch) (0.12 ± 0.003 inch)
34.00 ± 0.50 mm 101.60 ± 0.08 mm 4.00 ± 0.250 mm 1.60 ± 0.40 mm
9P-0071 9P-0071
49.66 ± 0.25 mm 101.60 ± 0.08 mm 4.80 ± 0.050 mm 4.80 ± 0.050 mm
9U-0346 9U-0346
41.5 ± 0.5 mm 108.5 ± 0.5 mm 6.65 ± 0.25 mm 3.00 ± 0.50 mm
107-5610 6W-4281
107-5614 107-5614 51.46 ± 0.50 mm 101.60 ± 0.08 mm 4.00 ± 0.50 mm .80 ± 0.20 mm
30.23 ± 0.25 mm 101.60 ± 0.08 mm 3.00 ± 0.25 mm 3.00 ± 0.25 mm
107-6356 107-5613
30.00 ± 0.50 mm 107.95 ± 0.10 mm 2.98 ± 0.02 mm 1.60 ± 0.40 mm
110-2141 110-2141
31.00 ± 0.50 mm 107.95 ± 0.025 mm 3.00 ± 0.50 mm 1.60 ± 0.40 mm
134-4077 134-4077
36.00 ± 0.50 mm 76.20 ± 0.08 mm 6.05 ± 0.50 mm
148-8889 149-0735 —
(1.42 ± 0.02 inch) (3.00 ± 0.003 inch) (0.24 ± 0.02 inch)
51.46 ± 0.50 mm 101.60 ± 0.08 mm 4.00 ± 0.50 mm 3.00 ± 0.25 mm
156-3640 156-3640
29.20 ± 0.25 mm 107.95 ± 0.13 mm 3.00 ± 0.50 mm .80 ± 0.20 mm
158-0424 158-0425
49.66 ± 0.25 mm 101.60 ± 0.08 mm 4.80 ± 0.050 mm 4.80 ± 0.050 mm
171-3941 171-3941
49.66 ± 0.25 mm 101.60 ± 0.08 mm 4.80 ± 0.050 mm 4.80 ± 0.050 mm
173-0714 173-0714
30.23 ± 0.25 mm 101.60 ± 0.08 mm 3.00 ± 0.25 mm 3.00 ± 0.25 mm
174-3405 174-3404
49.66 ± 0.25 mm 101.60 ± 0.08 mm 5.00 ± 0.50 mm .80 ± 0.20 mm
178-6352 178-6352
51.0 ± 0.25 mm 97.0 ± 0.08 mm 3.5 ± 0.50 mm
253-5413 233-8102 3.0 mm (0.12 inch)
(2.01 ± 0.01 inch) (3.82 ± 0.003 inch) (0.14 ± 0.020 inch)
41.10 ± 0.50 mm 109.50 ± 0.50 mm 2.80 ± 0.50 mm .80 ± 0.20 mm
271-1573 7T-5646
29.20 ± 0.25 mm 107.95 ± 0.13 mm 3.00 ± 0.50 mm .80 ± 0.20 mm
358-3824 358-3825
33.06 ± 0.25 mm 85.72 ± 0.08 mm 3.0 ± 0.25 mm
308-6000 308-5846 15°
(1.301 ± 0.009 inch) (3.375 ± 0.003 inch) (0.118 ± 0.009 inch)
36.00 ± 0.50 mm 76.20 ± 0.08 mm 6.05 ± 0.50 mm
360-8791 365-3046 —
(1.42 ± 0.02 inch) (3.00 ± 0.003 inch) (0.24 ± 0.02 inch)
364-4406 364-4406 32 mm (1.26 inch) 90 mm (3.54 inch) — —
365-1297 364-4407 32 mm (1.26 inch) 90 mm (3.54 inch) — —
65.6 ± 1 mm 76.2 ± 0.08 mm 3.5 ± 0.08 mm
483-1058 501-9091 3.0 mm (0.12 inch) Max
(2.58 ± 0.04 inch) (3.00 ± 0.003 inch) (0.138 ± 0.003 inch)
36 ± 1 mm 76.2 ± 0.08 mm 3.5 ± 0.08 mm
486-2947 486-2946 3.0 mm (0.12 inch) Max
(1.417 ± 0.04 inch) (3.00 ± 0.003 inch) (0.138 ± 0.003 inch)
38.50 ± 0.25 mm 72.0 ± 0.13 mm 4.0 ± 0.5 mm 1.0 ± 0.2 mm
— 106-0721
38.0 ± 0.5 mm 101.60 ± 0.08 mm 1.6 ± 0.4 mm
— 250-3220 —
(1.50 ± 0.02 inch) (4.00 ± 0.003 inch) (0.06 ± 0.02 inch)
255-0777 25.5 ± 0.25 mm 132.4 ± 0.05 mm 1.50 ± 0.5 mm .8 ± 0.2 mm
—
447-7091 (1.00 ± 0.010 inch) (5.21 ± 0.002 inch) (0.060 ± 0.02 inch) (0.03 ± 0.008 inch)
41.1 ± 0.5 mm 107.95 ± 0.1 mm 2.0 ± 0.5 mm .8 ± 0.2 mm
— 287-4002
28.0 mm 145.0 ± 0.1 mm
— 488-0171 — 20°
(1.102 inch) (5.709 ± 0.004 inch)
Table 9
Part Yoke Dimension Dimension D

Dimension A Dimension B
Number Number C Radius
31.75 ± 0.25 mm 79.38 ± 0.08 mm 1.52 ± 0.25 mm
323-2169 3P-8143 —
(1.25 ± 0.01 inch) (3.13 ± 0.003 inch) (0.06 ± 0.01 inch)
3P-8142 3P-8142
21.82 ± 0.25 mm 79.38 ± 0.08 mm 1.50 ± 0.25 mm
6Y-8972 6Y-8972 —
(0.86 ± 0.01 inch) (3.13 ± 0.003 inch) (0.06 ± 0.01 inch)
9G-8507 9G-8507
21.5 ± 0.25 mm 76.2 ± 0.08 mm 1.2 ± 0.3 mm
148-9319 148-9318 —
(0.85 ± 0.0010 inch) (3.0 ± 0.003 inch) (0.047 ± 0.012 inch)
21.82 ± 0.25 mm 79.38 ± 0.08 mm 1.50 ± 0.25 mm
250-3221 250-3221 —
(0.86 ± 0.01 inch) (3.13 ± 0.003 inch) (0.06 ± 0.01 inch)
21.82 ± 0.25 mm 79.38 ± 0.08 mm
441-9224 441-9225 — 1.5 mm (0.059 inch)
(0.859 ± 0.010 inch) (3.125 ± 0.003 inch)
Table 10


3K-9917 3K-9663 19.00 ± 0.08 mm 102.11 ± 0.03 mm 3.05 ± 0.25 mm 2.29 ± 0.51 mm
7K-1261 7K-1261 (0.75 ± 0.003 inch) (4.02 ± 0.001 inch) (0.12 ± 0.01 inch) (0.09 ± 0.02 inch)
24 ± 0.25 mm 101.6 ± 0.08 mm 3.00 ± 0.5 mm 2.00 ± 0.5 mm
3T-8034 3T-8034
19.81 ± 0.25 mm 101.60 ± 0.08 mm 1.50 ± 0.25 mm 1.50 ± 0.25 mm
6D-9818 6D-9819
7.00 ± 0.25 mm 75.70 ± 0.03 mm 2.39 ± 0.25 mm 3.00 ± 0.50 mm
6I-8053 6I-8052
17.53 ± 0.50 mm 102.21 ± 0.13 mm 3.00 ± 0.25 mm 2.29 ± 0.51 mm
6S-0335 6S-0286
37.5 ± 0.5 mm 69.85 ± 0.08 mm 3.00 ± 0.5 mm 3.00 ± 0.5 mm
108-8297 108-8297
19.00 ± 0.25 mm 111.13 ± 0.08 mm 2.10 ± 0.25 mm 2.50 ± 0.50 mm
117-5793 117-5793
(0.75 ± 0.01 inch) (4.38 ± 0.003 inch) (0.08 ± 0.01inch) (0.10 ± 0.02 inch)
27.00 ± 0.25 mm 127.00 ± 0.10 mm 2.10 ± 0.04 mm 2.50 ± 0.50 mm
118-2109 118-2109
21.00 ± 0.05 mm 101.60 ± 0.05 mm 1.50 ± 0.25 mm 4.00 ± 0.25 mm
131-8246 131-8247
47.50 ± 0.50 mm 107.95 ± 0.10 mm 1.60 ± 0.40 mm 2.50 ± 0.50 mm
155-2077 155-2077
(1.87± 0.02 inch) (4.25 ± 0.004 inch) (0.06± 0.02 inch) (0.10 ± 0.02 inch)
47.50 ± 0.50 mm 107.95 ± 0.10 mm 1.60 ± 0.40 mm 2.50 ± 0.50 mm
329-3804 329-3804
(1.87± 0.02 inch) (4.25 ± 0.004 inch) (0.06± 0.02 inch) (0.10 ± 0.02 inch)
Table 11

39.00 ± 0.25 mm 101.60 ± 0.08 mm 2.00 ± 0.250 mm 3.00 mm max
110-9311 110-9310
(1.54 ± 0.01 inch) (4.00 ± 0.003 inch) (0.07874 ± 0.00984 inch) (0.12 inch max)
Table 12
Dimension
Part Yoke
Dimension A Dimension B Dimension C D
Number Number
Radius
0.5 mm
39 ± 0.25 mm 85.72 ± 0.08 mm 3.0 ± 0.25 mm
308-6005 308-5851 (0.019 inch)
(1.535 ± 0.009 inch) (3.374 ± 0.003 inch) (0.118 ± 0.009 inch)
Max
Table 13
Thermal Spray Procedure

Part Description
Base Metal Steel Forging
Hardness 23-28 Rc
Table 14
Arc Spray Equipment and Procedure

Arc Spray Equipment
Maximum Surface Texture 6.1 µm (240.00 µinch)
Reason for Spraying Seal Wear
Mating Part Contact Area & Material Seal
SmartArc by Oerlikon Metco,TAFA 8830 MHU,
Arc Spray Equipment Type
or TAFA 8835 MHU
TAFA Alcro Wire Top Coat; TAFA 75B Bond
Wire
Coat
Finish Thickness As Required
Finishing Allowance 0.51 to 0.64 mm (0.020 to 0.025 inch) per side
Spray Angle 70° to 90°
66° C (150° F) Do not direct arc on area to be
Substrate Pre-Heat Temperature
sprayed
Substrate Temperature During
148° C (300° F)
Spraying Not to Exceed
Auxiliary Cooling Filtered shop air
Rotation/Traverse Device Lathe
Rotation Speed 92.0 SMPM (300.00 SFPM)
Surface Preparation Method Undercut and Grit blast
Machining Method Machine
Equipment Required Turn (Horizontal or Vertical) Lathe
Recommended Cutting Tool ISCAR DNMG 432 TF IC507
Blast Media Recommendation Pressure Type Only (Aluminum Oxide Grit)
Grinding Equipment Dunmore Tool Post Grinder
Recommended Abrasive Norton 32A 46-H8VBE
1) No lead on grinding
Remarks 2) Roundness specification of 0.05 mm
(0.002 inch)
Table 15
Check
Arc Spray Procedure
List
Clean Part Degrease in hot Aluminum safe cleaner
Undercut If desired
Chamfer 30°
Remove Oxide Use fiber flap brush or Clean/strip disc
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 to 150 mm (2.0 to 6.0 inch)
Distance
Remove Blast Mask Make sure that surface is clean
Mask for Metal Spray Antibond or Blue Layout Dye
Metal Spray Equipment Smart Arc by
TAFA
Type Oerlikon 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 Alcro TAFA Alcro
Clamp Pressure 275 kPa (40 psi)
Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 30V 29V
Amps 150 Amps 125 Amps
Gun to Work Distance
76.2 mm (3.00 inch) 76.2 mm (3.00 inch)
(Standoff)
0.038 mm 0.038 mm
Spray Rate/Build Up
(0.0015 inch)/pass (0.0015 inch)/pass
Rotation Speed of Part RPM varies depending on diameter (52 to 143
(RPM) 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 Lathe
Part/Cutter Rotation
50 SMPM (150.00 SFPM)
Roughing
75 SMPM (250.00 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)
Additional Finish Method Grind surface for no lead
Table 16
Flame Spray Equipment and Procedure

Flame Spray Equipment
Maximum Surface Texture 6.1 µm (240.00 µinch)
Reason for Spraying Seal Wear
Mating Part Contact Area & Material Seal
Oerlikon Metco Equipment Type 6P-II by Oerlikon Metco
Metco Material Metco 453
Metco Sealer -
Finish Thickness As Required
0.51 to 0.64 mm (0.020 to 0.025 inch) per
Finishing Allowance
side
Spray Angle 70° to 90°
66° C (150° F) Do not direct flame on area
Substrate Pre-Heat Temperature
to be sprayed
Substrate Temperature During Spraying
148° C (300° F)
Not to Exceed
Auxiliary Cooling If desired
Rotation/Traverse Device Lathe
Rotation/Traverse Speed 92.0 SMPM (300.00 SFPM)
Surface Preparation Method Undercut and Grit Blast
Finishing Method Machine
Machining Equipment Type Lathe
Recommended Cutter Grade C-2, 883 Carboloy or equivalent
1) No lead on grinding
Remarks 2) Roundness specification of 0.05 mm
(0.002 inch)
Table 17
Flame Spray Process Check

Procedure
(6P) List
Clean Part Degrease in hot caustic solution
Undercut To "tru-up" surface
Chamfer 30°
Remove Oxide Use fiber flap brush or Clean/strip disc
Clean Spray Area Metco cleaning solvent or equivalent
Mask for Grit Blast Duct Tape
Grit Blast Equipment Pressure
Grit Type and Size 25 to 40 steel angular grit
Blast Air Pressure 620 kPa (90.0 psi)
Blast Nozzle to Work
50 mm (2.0 inch)
Distance
Remove Blast Mask Make sure that surface is clean
Mask for Metal Spray Metco Antibond
Metal Spray Equipment 6P-II Hand Held Thermo Spray System by
Type Oerlikon Metco
Auxiliary Cooling If desired
Nozzle 6P-C7A-K "K" Nozzle
6P-3/Cooling Air 140 - 170 kPa
Air Capacity/Pressure
(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)
5.5 kg (12 lb) per hour or 90 gr (3.2 oz) per
Spray Rate/Build Up
min
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed of Part RPM varies depending on diameter (70 - 143
(RPM) RPM)
Rotation Speed of Part
92 SMPM (300.00 SFPM)
(SFPM)
Traverse Rate of Gun
15.0 SMPM (50.00 SFPM)
(SFPM)
Gun Fixturing Method Machine mount
0.10 to 0.15 mm (0.004 to 0.006 inch) per
Top Coat/Thickness
pass
Finishing Equipment Lathe
92.0 SMPM (300.00 SFPM)
(SFPM)
0.05 to 0.10 mm (0.002 to 0.004 inch) per
Traverse Speed
revolution
Depth of Rough Cut 0.38 to 0.51 mm (0.015 to 0.020 inch) per side
Depth of Finish Cut 0.25 to 0.38 mm (0.010 to 0.015 inch) per side
Additional Finish Method Emery cloth for desired finish, no lead
Table 18
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 five major crack detection methods or Non-Destructive Testing (NDT) listed in
this section: Visual Surface Inspection (VT), Liquid Penetrant Testing (PT), Dry / Wet
Magnetic Particle Testing (MPT), and Ultrasonic Testing (UT).
Crack detection methods or NDT is methods for testing components for cracks without
damaging the component. VT, PT, Dry/ Wet MPT, and UT are methods recommended.
There may be more than one acceptable crack detection method for the testing of a given
part, although PT is the most versatile. For example, the PT method can be used when
testing smooth machined components such as shafts, gear teeth, and splines, but using
the Wet MPT is more accurate. Refer to Table 19 for advantages and disadvantages and
Table 20 for standards and requirements for these NDT methods.
Crack Detection Methods Advantages vs. Disadvantages

Detection
Advantages Disadvantages
Method
- Least Expensive
Visual - Detects most - Limited to surface-only defects.
Surface damaging defects. - Requires inspectors to have broad knowledge
Inspection - Immediate Results of welding and fabrication in addition to Non-
(VT) - Minimum part Destructive Testing (NDT).
preparation
- Inexpensive
Liquid
- Minimal Training - Least Sensitive
Penetrant
- Portable - Detects surface cracks only.
Testing
- Works on - Rough or porous surfaces interfere with test
(PT)
nonmagnetic material.
- Portable
Dry - Fast/Immediate
- Works on magnetic material only.
Magnetic Results
- Less sensitive than Wet Magnetic Particle
Particle - Detects surface and
Testing (MPT).
(MPT) subsurface
discontinuities
- More sensitive than
Wet Liquid Penetrant - Requires power for light.
Magnetic Testing (PT). - Works on magnetic material only.
Particle - Detects subsurface - Liquid composition and agitation must be
(MPT) as much as 0.13 mm monitored.
(0.005 inch).
- Most Sensitive
- Detects deep
material defects.
Ultrasonic - Most Expensive
- Immediate Results
Testing - Requires operator training and certification.
- Wide range of
(UT) - Surface must be accessible to probe
materials and
thickness can be
inspected
Table 19
Applicable Crack Detection Standards
Minimum
Detection Acceptance Required
Standard
Method Criteria Personnel
Qualifications
EN-ISO 9712
Visual Surface EN-ISO 5817 EN-ISO 5817 - Level B
ANSI-ASNT
Inspection (VT) AWS D1.1 AWS D1.1 - Table 6.1
SNT-TC-1A
EN-ISO 9712
Liquid Penetrant EN-ISO 3452 EN-ISO 23277
ANSI-ASNT
Testing (PT) ASTM E165 AWS - D1.1
SNT-TC-1A
EN-ISO 9712
Magnetic Particle EN-ISO 17638 EN-ISO 23278 - Level 1
ANSI-ASNT
Testing (MPT) ASTM E709 AWS D1.1 - Table 6.1
SNT-TC-1A
EN-ISO 11666 Technique
EN-ISO 17640 - EN-ISO 9712
Ultrasonic Testing 2 - Level 2
Level B ANSI-ASNT
(UT) AWS D1.1 - Class A -
AWS D1.1 SNT-TC-1A
Table 6.3
Table 20
Visual Surface Inspection (VT)

Example of Visual Surface Inspection (VT) Tooling
(A) Flashlight (or adequate light source)
(B) Magnifying Glass
(C) Tape Measure (or other measuring device)
(D) Inspection Mirror
Refer to Tooling and Equipment Table 3 for part numbers.
Components and welds that are to be tested using PT, MPT, or UT shall first be subject to
a Visual Surface Inspection (VT). VT is often the most cost-effective inspection method
and requires little equipment as seen in Illustration 35. 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)
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

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
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.
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.
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.
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.
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 40. Clean the area of application of the developer with solvent cleaner.
Dry Magnetic Particle Testing (MPT)

Materials and Equipment Required
(A) Indications shown by Dry Magnetic Particle Testing (MPT).
(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 (MPT)

Materials and Equipment
Refer to Tooling and Equipment Table "Tooling and Equipment" for part numbers.
(A) Indications shown by Wet Magnetic Particle Testing (MPT).
(B) Electromagnetic Yoke
(D) Ultraviolet Lamp
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:
a. The concentration of the suspended magnetic particles shall be as specified

by the manufacturer and be checked by settling volume measurements.
b. Concentrations are determined by measuring the settling volume by using an

ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL
(0.0017 oz) divisions, refer to Illustration 43. 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.
c. Wet magnetic particles may be suspended in a low viscosity oil or conditioned

water.
d. The oil shall have the following characteristics:
Low viscosity not to exceed 5 mm2/s (5 cSt) at any temperature at which

the vehicle is to be used.
Low inherent fluorescence and be non-reactive.
e. The conditioning agents used in the conditioned water shall have the following
characteristics:
Impart good wetting characteristics and good dispersion.
Minimize foaming and be non-corrosive.
Low viscosity shall not exceed a maximum viscosity of 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.
Yoke applied the area to be inspected.
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 44 for an example of yoke placement.
4. Visually inspect for indications of discontinuities using the proper illumination.
5. Record the size and shape of any discontinuities found.
Ultrasonic Testing (UT)

Note: Crack depth cannot be accurately determined by UT, only full depth cracking can
be consistently determined. For cracks that are not full depth, an indication of a partial
depth cracks can be detected by an experienced technician. Refer to Table 20 for crack
detection standards.
1. Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short

ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect
the thickness of the object. Ultrasonic testing consists of an ultrasound transducer
connected to a diagnostic machine and passed over the object being inspected.
2. There are two methods of receiving the ultrasound waveform from the transducer:
reflection and attenuation.
a. Reflection - Ultrasonic pulses exit the transducer and travel throughout the
thickness of the material. When the sound waves propagate into an object
being tested, the waves return to the transducer when a discontinuity is
discovered along the sonic path. These waves continue and reflect from the
back surface of the material to project the thickness of the material.
b. Attenuation - A transmitter sends ultrasound through one surface, and a

separate receiver detects the amount that has reached it on another surface
after traveling through the medium. Any discontinuities or other conditions
within the medium will reduce the amount of sound transmitted, revealing the
presence of the imperfections.

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Procedure to Machine Damaged Transmission and Differential Yokes {3030,

SMCS - 3258,3253,3030 i07713919

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

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

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

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

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

772D (S/N: 5HR1-UP)

773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP; 7FZ1-UP)

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

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

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

777 (S/N: 84A1-UP)

783B (S/N: 8YM1-UP)

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

787B (S/N: 9TM1-UP)

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

793D (S/N: FDB1-UP)

797B (S/N: JSM1-UP)

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

Information contained in this document is considered Caterpillar: Confidential

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

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Caterpillar cannot anticipate every possible circumstance that might involve a

Reuse and Salvage Guidelines

Tooling and Equipment

To avoid component damage, follow the recommended

Required Tooling and Equipment

— GO/NO-GO Thread Gauge Set,

Prepare the Area for Inspection

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

Personal injury can result from air pressure.

Personal injury can result without following proper procedure.

During cleaning, do not damage machined surfaces.

Use pressurized air to dry parts.

Use appropriate thread taps to chase all threaded holes.

Standardized Parts Marking Procedure

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

Repairing Shaft Seal Wear

Wear Sleeves and Wear Sleeve Drivers

Application Chart by Reference to Shaft Size

Sleeve Part Sleeve

Seal Surface Repair Sleeves

Wear Sleeve Installation

Metal Spray Method to Repair Seal Surfaces

Note: (C*) is when the other is not given.

Refer to Illustration 27 for dimensions listed in Table 6.

Transmission and Differential Yokes

Part Yoke Dimension D

Note: (C*) is when the other is not given.

Refer to Illustration 28 for dimensions listed in Table 7.

Transmission and Differential Yokes

Part Yoke Dimension D