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Reuse Final Drive

This document provides guidelines for the reuse and salvage of planetary final drives for specific wheeled models, aiming to help Caterpillar dealers establish a parts reusability program. It includes safety information, inspection procedures, and necessary tooling for evaluating the reusability of components. The guidelines emphasize the importance of adhering to specifications and performing visual inspections to determine if parts can be reused safely.

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0% found this document useful (0 votes)

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Reuse Final Drive

Uploaded by

jhon

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 65

Por NPR - SEBF8093 - Reuse and Salvage of Planetary Final Drives for Certain Whe...

Page 1 of 65

Cerrar SIS

Pantalla anterior

Producto: NO SE HA ESCOGIDO NINGUN EQUIPO

Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO

Pautas de reutilización y recuperación

Reuse and Salvage of Planetary Final Drives for Certain Wheeled Models {0679, 4011, 4050, 4051, 4201, 4205, 4215}
Número de medio -SEBF8093-15 Fecha de publicación -06/10/2014 Fecha de actualización -27/10/2020

i08254462

Reuse and Salvage of Planetary Final Drives for Certain Wheeled Models {0679, 4011, 4050,
4051, 4201, 4205, 4215}
SMCS - 0679; 4011; 4050; 4051; 4201; 4205; 4215

Articulated Truck
All
Compact Wheel Loader
All
Earthmoving Compactor
All
Integrated Toolcarrier
All
Landfill Compactor
All
Load Haul Dump
All
Soil Compactor
All
Underground Articulated Truck
All
Wheel Dozer
All
Wheel Loader
All

Revision History:

Table 1
Revision Summary of Changes
The wheel inspection content contained in SEBF8958, "Repair Procedures of Wheel Bolt Holes for 992, 993K and 994 Wheel
Loaders" has been added to this document.
15
Added serial number prefix ZLK
Added 15 new part numbers to Tables 5 through 8 and 19 through 26.
Changed title from "Planetary Final Drives for Wheel Loaders, Wheel Tractors, Compactors, Underground Articulated Trucks" to
"Reuse and Salvage of Planetary Final Drives for Certain Wheeled Models"
The information contained within the following have been moved and combined into this document:
- SEBF2149, "Thermal Spray Procedures for Wheel Loader - Wheel Bearing ID Bore"
- SEBF2151, "Thermal Spray Procedures for Wheel Loader Spindle (OD)"
- SEBF2192, "Thermal Spray Procedures for IT And Wheel Dozer Spindle"
- SEBF2193, "Thermal Spray Procedures for Wheel Bores on IT, Wheel Dozer, and Compactors"
14
- SEBF8090, "Wheel Loader Power Train Specifications: 966C, 966D, 966E, 980C, 988B, 992, 992B, 992C"
- SEBF8841, "Reuse and Salvage for the Wheel Loader and Intergrated Tool Carrier Axel Shaft"
- SEBF9262, "Thermal Spray Procedures of Wheel, Spindle, and Hub Assembly Bearing Surfaces for Certain Wheel and Final
Drive Groups"
- SEBF9301, "Thermal Spray Procedures for Wheel Dozer, Integrated Toolcarrier, and Wheel Tractor Scraper Hub"
Added new serial number prefixes
Updated Tables 4, 5, 7, 8,20,22,24, 25 and 26.
Updated boilerplate information, added clarity to Illustrations, tables, verbiage, and document layout. Corrected several
13
Tolerances throughout this document. Added information for 20 part numbers.
12 Added 22 part numbers.
11 Added 3 part numbers.
10 Added 10 part numbers.

Introduction
© 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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 19-06-2023
Por NPR - SEBF8093 - Reuse and Salvage of Planetary Final Drives for Certain Whe... Page 2 of 65

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.

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!

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 planetary carrier in the final drive. 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.

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

References
Table 2
References
Media Number Publication Type & Title
"Gear Tooth Inspection"
Channel1
https://channel1.mediaspace.kaltura.com/media/Gear+Tooth+Inspection/1_5ujdi5zp
"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
SEBF8163
"Procedures to Salvage Thrust Faces on Planetary Carriers"
Reuse and Salvage Guidelines
SEBF8187
"Standardized Parts Marking Procedures"
Reuse and Salvage Guidelines
SEBF8193
"Reusability of Drive Train Gears"
Reuse and Salvage Guidelines
SEBF8728
"Specifications for Inspection of Driveline Fasteners"
Reuse and Salvage Guidelines
SEBF9238
"Fundamentals of Arc Spray for reconditioning Components"
Reuse and Salvage Guidelines
SEBF9240
"Fundamentals of Flame Spray for Reconditioning Components"

Service Advisories, Service Letters, and Technical Service Bulletins

NOTICE

The most recent Service Advisories, Service Letters, and Technical

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

Tooling and Equipment

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

Table 3
Required Tooling and Equipment
Part Number Description Designation
— (1) Personal Protective Equipment (PPE) Personal Protection
Component
— (2) Clevis/ Shackle Repositioning
and Movement
Component
— (2) Lifting Eye Assemblies Repositioning
and Movement
Component
— (2) Tool (Cribbing) Repositioning
and Movement
Component
— Suitable Lifting Device Repositioning
and Movement
1U-7262 Telescoping Magnet General Tooling
Automatic Tape Measure (1-inch X 26- ft) Measurement
1U-9367
25.4- mm x 8- m Checks
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
473-8692 Micrometer, Outside - Digital Measurement
152.4 - 304.8 mm (6.00 - 12.00 inch) Checks
Instrument Group
Micrometer, Inside
474-3709 (8.00 - 32.00 inch) Internal
or Measurement
474-3710 Instrument Group Checks
Micrometer, Inside
200 - 800 mm
Tool (Level)
385-8484 Level
305 mm (12 inch)
GO/NO-GO Thread Gauge Set, Metric Threaded Hole
Inspection
GO/NO-GO Thread Gauge Set, SAE

—
and /or
—
Threaded Hole
— (2) Plastic Plug Assortment
Protection
Threaded Hole
— (2) Tap and Die Set
/ Restore
Threaded Shaft
154-9316 File Metric
/ 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
Surface
1U-6791 Grinding Wheel Preparation
/ De-burring
Surface
1U-6794 Grinding Wheel Preparation
/ De-burring
Surface
1U-6832 Abrasive Disc Preparation
/ De-burring
Surface
1U-6846 Abrasive Disc Preparation
/ De-burring
Surface
4C-3770 Grinding Wheel 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
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 (3) Metal Marking Pen Parts Marking
6V-2010 Polishing Stone Gear Polishing
1U-9918 Brush General Cleaning
Abrasive Material
467-0158 General Cleaning
Roll
8T-7765 Surface Reconditioning Pad (180 Grit) General Cleaning
162-5791 Towel General Cleaning
MOP Small Gear/
— Large Rubber Band Spline Wear
Inspection
Measurement
Tool Group Between / MOP
549-3500
Gage Pins Gear/ Spline
Wear Inspection
Precision Gage Pins (4) Measurement
Ø 2.3825 mm Between / MOP
—
(0.09380 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection

Precision Gage Pins (4) Measurement

Ø 3.1750 mm Between / MOP
—
(0.12500 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 3.6576 mm Between / MOP
—
(0.14400 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 3.9675 mm Between / MOP
—
(0.15620 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Measurement
Pin Set Between / MOP
549-3505 (5)
4.0 mm Gear/ Spline
Wear Inspection
Precision Gage Pins (4) Measurement
Ø 4.0640 mm Between / MOP
—
(0.16000 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 4.7625 mm Between / MOP
—
(0.18750 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 4.7630 mm Between / MOP
—
(0.18752 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 4.8768 mm Between / MOP
—
(0.19200 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 4.877 mm Between / MOP
—
(0.19201 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Measurement
Pin Set Between / MOP
549-3506 (5)
5.0 mm Gear/ Spline
Wear Inspection
Precision Gage Pins (4) Measurement
5.4864 mm Between / MOP
—
(0.21600 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Measurement
Pin Set Between / MOP
549-3508 (5)
6.0 mm Gear/ Spline
Wear Inspection
Precision Gage Pins (4) Measurement
Ø 6.0960 mm Between / MOP
—
(0.24000 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 6.3500 mm Between / MOP
—
(0.25000 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 7.3152 mm Between / MOP
—
(0.28800 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 7.9375 mm Between / MOP
—
(0.31250 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 8.7782 mm Between / MOP
—
(0.34560 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection

— Precision Gage Pins (4) Measurement

Ø 9.5250 mm Between / MOP
(0.37500 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 9.7536 mm Between / MOP
—
(0.38400 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Measurement
(5) Pin Set Between / MOP
549-3512
10.0 mm Gear/ Spline
Wear Inspection
Precision Gage Pins (4) Measurement
Ø 10.9728 mm Between / MOP
—
(0.43200 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 11.1125 mm Between / MOP
—
(0.43750 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Measurement
(5) Pin Set Between / MOP
549-3513
12.0 mm Gear/ Spline
Wear Inspection
Precision Gage Pins (4) Measurement
Ø 12.7000 mm Between / MOP
—
(0.50000 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 14.0000 mm Between / MOP
—
(0.55118 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 14.2875 mm Between / MOP
—
(0.56250 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Precision Gage Pins (4) Measurement
Ø 15.9995 mm Between / MOP
—
(0.62990 inch) Gear/ Spline
x 50.8 mm (2.00 inch) Wear Inspection
Measurement
(5) Pin Set Between / MOP
549-3514
16.0 mm Gear/ Spline
Wear Inspection
Measurement
Pin Set Between / MOP
549-3515 (5)
20.0 mm Gear/ Spline
Wear Inspection
Measurement
Pin Set Between / MOP
549-3516 (5)
25.0 mm Gear/ Spline
Wear Inspection
Measurement
(5) (6) Between / MOP
549-3520 Tool (Magnet)
Gear/ Spline
Wear Inspection
Measurement
Between / MOP
— Magnets
Large Gear/ Spline
Wear Inspection
Seal Pick Gear/ Shaft
5P-7414
Kit Step Inspection
Surface Texture
9A-1593 Comparison Gauge (Surface Texture)
Tester
Tool Surface Texture
453-5376
Specimen Tester
448-3698

Indicator Surface Texture

(Profilometer) Tester
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
— (2) 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
263-7184 Crack Detection Kit (Magnetic Particle) Particle Testing
(MT)
Dry Magnetic
— Paint Pen Particle Testing
(MT)
Wet Magnetic
Lamp Group
459-0184 Particle Testing
Ultraviolet
(MT)
Fluid Ultrasonic
505-8671
Ultrasonic Wear Indicator Testing (UT)
Ultrasonic
415-4055 Tool Group(Ultrasonic)
Testing (UT)
(1)
Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety
standards.
(2)
Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
(3)
Available in the United States only.
(4)
Minimum of two are required.
(5)
Part of Tool Group 549-3500.
(6)
For use with precision gage pins.

Preparation Recommendations

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.

Note: Clean exterior of the planetary final drive prior to disassembly.

• Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A
surface irregularity can hide the indication of an unacceptable defect.

• Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the
part.

• During cleaning, do not damage machined surfaces.

• Do not use pressurized air to dry internal components. Compressed air has moisture and contaminants that can cause premature failure of
internal components.

• Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately after cleaning. Carefully store the
parts in a clean container.

• Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting from rust,
nicks, and dents.

• Use appropriate thread taps to chase all threaded holes.

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.

Illustration 3 g06124077
DO NOT use numbering stamp punches to mark internal components.

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

Example 1

Illustration 4 g03856853
Typical Example

Illustration 4 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were
15,000 hours on the gear at the time of rebuild.

Example 2

Illustration 5 g03856857
Typical Example

Illustration 5 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 5. In this example, the gear has a total of
22,000 hours.

Example 3

Illustration 6 g03519882
Typical Example

(A) Mark the planet pin on either end.

Final Drive Wheel Group Component Locations

Illustration 7 g06320845
Typical Example of Final Drive Wheel Group - Without Brakes
(1) Spindle
(2) Wheel
(3) Reaction Hub
(4) Planetary Carrier
(5) Planetary Gear
(6) Planetary Shaft

Illustration 8 g06321222
Typical Example of Final Drive Wheel Group - With Brakes
(1) Spindle
(2) Wheel
(3) Hub
(4) Planetary Carrier
(5) Planetary Gear
(6) Planetary Shaft
(7) Service Brake Group

Measurement Techniques

NOTICE

Precise measurements shall be made when the component and

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

Measurement Tooling Calibration

Outside Micrometers

Illustration 9 g06208395
Typical example of calibrating outside micrometer (A).
(A) Outside Micrometer

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

Inside Micrometer

Illustration 10 g06208411
Typical example of calibrating inside micrometer (B).
(B) Inside Micrometer

Bore Diameters

Illustration 11 g06318221
Typical example of measuring bore Inside Dimension (ID) of a wheel.
(A) Indicates the diameter of the bore.
(B) Indicates the overall thickness of the material.

Note: Measurements taken on the edge of a bore may not give an accurate measurement.

Take measurements at locations (A1), (A2), and (A3).

Then take measurements at locations (A4), (A5), and (A6).

To ensure adequate life of the components, this document contains precise tolerances for measurements taken on various features. Ensure that several
sample measurements are taken at different locations on the same feature. Measure diameters of internal bores in six places to identify tapered and or
oval conditions. Refer to Illustration 11.

Shaft and Journal Diameters

Illustration 12 g06318222
Typical example of measuring an Outside Diameter (OD) Dimension of a spindle.
(C) Indicates the diameter of the shaft.
(D) Indicates the overall measurable length of the shaft journal.

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

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

To ensure adequate life of the components, this document contains precise tolerances for measurements taken on various features. Ensure that several
sample measurements are taken at different locations on the same feature. Measure diameters of journals in six places to identify tapered and or oval
conditions. Refer to Illustration 12.

Specification of the Pin Bore of the Planetary Carrier

Pin Bore Inspection

Bores will usually show a contact area from the shaft that may be worn slightly. The bore may also have damage from some broaching, fretting,
adhesion, or impact. If any of the following conditions exist, the planetary carrier shall not be reused:

• The bore has a that will stop a seal pick.

• The shaft has spun in the bore.

• The bore is elongated or cracked.

• Significant damage from some broaching or fretting is present in the bore.

• The pin bore exceeds the specifications for new parts.

Inspection Procedure

Complete the following steps to inspect the pin bore.

1. Clean the pin bore thoroughly before inspecting.

Pin bores and pins can be cleaned with cleaner for parts and a surface reconditioning pad that will not remove metal.

2. Visually inspect the bore for damage and wear.

Note: An adequate light source is necessary to inspect pin bores. An optical magnifier may also be used.

3. Inspect the bore with a seal pick to detect any s.

Refer to Table 5 for a summary of the specifications of the pin bores.

Reference: , SEBF8163Reuse and Salvage Guidelines, "Procedures to Salvage Thrust Faces on Planetary Carriers".

Summary of the Final Drive Planetary Carrier Pin Bore Tolerances

Illustration 13 g06319011
Typical example of an internal planetary carrier with in bores on a dual plane.
(A) Pin Bore

Table 4
Record Actual Dimensions
Final Drive Internal Planetary Carriers Pin Bore
Refer to the "Measurement Techniques" section for the proper techniques and number
Tolerances
of measurements to be taken.
Part
Tolerance
Number Measurement Measurement Measurement
(1) (A)

Ø 35.278 ± 0.01 mm
3P-2415 A1 = A2 = A3 =
(1.3889 ± 0.0004 inch)
Ø 42.342 ± 0.013 mm
4E-2166 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 47.216 ± 0.01 mm
6Y-1269 A1 = A2 = A3 =
(1.8589 ± 0.0004 inch)

7G-3801 Ø 35.278 ± 0.01 mm A1 = A2 = A3 =

(1.3889 ± 0.0004 inch)
Ø 35.279 ± 0.013 mm
8R-0233 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
8R-2198 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 35.279 ± 0.013 mm
8R-2537 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
8R-4571 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
8R-5959 Ø 77.605 ± 0.015 mm
A1 = A2 = A3 =
137-3506 (3.0553 ± 0.0006 inch)
Ø 120.03 ± 0.015 mm A1 = A2 = A3 =
8R-5960
(4.7256 ± 0.0006 inch)
Ø 48.007 ± 0.013 mm
9C-6027 A1 = A2 = A3 =
(1.8900 ± 0.0005 inch)
Ø 30.026 ± 0.013 mm
110-5187 A1 = A2 = A3 =
(1.1821 ± 0.0005 inch)
Ø 48.007 ± 0.013 mm
119-1096 A1 = A2 = A3 =
(1.8900 ± 0.0005 inch)
Ø 70.057 ± 0.013 mm
129-4300 A1 = A2 = A3 =
(2.7581 ± 0.0005 inch)
Ø 35.278 ± 0.01 mm
136-4838 A1 = A2 = A3 =
(1.3889 ± 0.0004 inch)
Ø 42.342 ± 0.013 mm
218-3174 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 77.605 ± 0.015 mm
244-1099 A1 = A2 = A3 =
(3.0553 ± 0.0006 inch)
Ø 42.418 ± 0.01 mm
255-8850 A1 = A2 = A3 =
(1.6700 ± 0.0004 inch)
Ø 53.015 ± 0.013 mm
270-7672 A1 = A2 = A3 =
(2.0872 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
327-2232 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
360-9857 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
361-8064 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
386-0500 (2.3388 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
364-2561 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
370-4416 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
386-0501 (2.3388 ± 0.0005 inch)
Ø 59.406 ± 0.013 mm
388-1399 A1 = A2 = A3 =
(2.3388 ± 0.0005 inch)
Ø 95.347 ± 0.015 mm
419-6354 A1 = A2 = A3 =
(3.7538 ± 0.0006 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Illustration 14 g06319028
Typical example of an external planetary carrier with in bores on a dual plane.
(B) Pin Bore

Table 5
Record Actual Dimensions
Final Drive External Planetary Carriers Pin Bore
Refer to the "Measurement Techniques" section for the proper techniques and number
Tolerances
of measurements to be taken.
Part Tolerance
Measurement Measurement Measurement
Number (1) (B)
1V-1409 Ø 31.768 ± 0.013 mm
A1 = A2 = A3 =
9K-4887 (1.2507 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
1V-2281 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 35.279 ± 0.013 mm
1V-3335 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 84.821 ± 0.013 mm
1V-5059 A1 = A2 = A3 =
(3.3394 ± 0.0005 inch)
Ø 77.605 ± 0.013 mm
2V-4149 A1 = A2 = A3 =
(3.0553 ± 0.0005 inch)
Ø 44.42 ± 0.013 mm
2V-5722 A1 = A2 = A3 =
(1.7488 ± 0.0005 inch)
Ø 84.821 ± 0.013 mm
3D-4222 A1 = A2 = A3 =
(3.3394 ± 0.0005 inch)
3P-7006 Ø 42.418 ± 0.010 mm
A1 = A2 = A3 =
193-8609 (1.670 ± 0.0004 inch)
3V-2065 Ø 52.339 ± 0.013 mm
A1 = A2 = A3 =
8R-4821 (2.0606 ± 0.0005 inch)
Ø 52.339 ± 0.013 mm
3V-5601 A1 = A2 = A3 =
(2.0606 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
4E-1709 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
4K-6389 Ø 42.342 ± 0.013 mm
A1 = A2 = A3 =
7K-1848 (1.6670 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
4V-8541 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 31.768 ± 0.013 mm
4V-9823 A1 = A2 = A3 =
(1.2507 ± 0.0005 inch)
Ø 47.216 ± 0.013 mm
4V-5237 A1 = A2 = A3 =
(1.8589 ± 0.0005 inch)
Ø 95.347 ± 0.013 mm
4V-9888 A1 = A2 = A3 =
(3.7538 ± 0.0005 inch)
4Y-0475 Ø 42.342 ± 0.013 mm
A1 = A2 = A3 =
5V-9361 (1.6670 ± 0.0005 inch)
5K-1522 Ø 42.342 ± 0.013 mm
A1 = A2 = A3 =
7K-1843 (1.6670 ± 0.0005 inch)
5V-4704 Ø 95.347 ± 0.013 mm
A1 = A2 = A3 =
9V-1396 (3.7538 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
5V-6177 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
6D-8363 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
8W-9697 (2.3388 ± 0.0005 inch)
Ø 35.279 ± 0.013 mm
6K-5837 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 35.279 ± 0.013 mm
6S-3011 A1 = A2 = A3 =
(1.3889 ± 0.0005 inch)
Ø 42.418 ± 0.01 mm
6T-3721 A1 = A2 = A3 =
(1.6700 ± 0.0004 inch)
7K-1847 Ø 52.339 ± 0.013 mm
A1 = A2 = A3 =
8R-4821 (2.0606 ± 0.0005 inch)

8K-5634 Ø 84.821 ± 0.013 mm A1 = A2 = A3 =

(3.3394 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
9K-1759 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
Ø 35.278 ± 0.01 mm
9P-5532 A1 = A2 = A3 =
(1.3889 ± 0.0004 nch)
Ø 95.347 ± 0.013 mm
9U-3389 A1 = A2 = A3 =
(3.7538 ± 0.0005 inch)
105-8709 Ø 59.406 ± 0.013 mm A1 = A2 = A3 =
468-4048 (2.3388 ± 0.0005 inch)
Ø 43.50 ± 0.13 mm
112-7308 A1 = A2 = A3 =
(1.7126 ± 0.0051 inch)
Ø 47.216 ± 0.01 mm
115-0760 A1 = A2 = A3 =
(1.8589 ± 0.0004 inch)
118-9402
Ø 77.605 ± 0.013 mm
162-0195 A1 = A2 = A3 =
(3.0553 ± 0.0005 inch)
162-0270
127-9799 Ø 95.347 ± 0.013 mm
A1 = A2 = A3 =
468-4053 (3.7538 ± 0.0005 inch)
129-3046 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
463-9184 (2.3388 ± 0.0005 inch)
180-0014 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
475-4918 (2.3388 ± 0.0005 inch)
Ø 42.342 ± 0.013 mm
190-5936 A1 = A2 = A3 =
(1.6670 ± 0.0005 inch)
200-0819 Ø 77.605 ± 0.013 mm
A1 = A2 = A3 =
467-4571 (3.0553 ± 0.0005 inch)
Ø 77.605 ± 0.13 mm
203-1795 A1 = A2 = A3 =
(3.0553 ± 0.005 inch)
Ø 110.1 ± 0.015 mm
244-1100 A1 = A2 = A3 =
(4.3346 ± 0.0006 inch)
Ø 120.03 ± 0.015 mm
419-6355 A1 = A2 = A3 =
(4.726 ± 0.0006 inch)
438-3417 Ø 59.406 ± 0.013 mm
A1 = A2 = A3 =
467-4794 (2.3388 ± 0.0005 inch)
Ø 77.605 ± 0.013 mm
468-4065 A1 = A2 = A3 =
(3.0553 ± 0.0005 inch)
Ø 59.406 ± 0.013 mm
469-1587 A1 = A2 = A3 =
(2.3388 ± 0.0005 inch)
Ø 77.605 ± 0.013 mm
562-1269 A1 = A2 = A3 =
(3.0553 ± 0.0005 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Illustration 15 g06319051
Typical example of a planetary carrier with pin bores on a single plane.
(C) Pin Bore

Table 6

Final Drive Planetary Carrier Pin Bore (Single Plane) Record Actual Dimensions
Tolerances Refer to the "Measurement Techniques" section for the proper techniques
and number of measurements to be taken.

Part Fit Tolerances

Number Limit (C) Measurement Measurement Measurement
(1) (2)
Minimum Maximum
216-8118 Ø 45.000 mm Ø 45.039 mm
H8 A1 = A2 = A3 =
292-5438 (1.7717 inch) (1.7732 inch)
Ø 39.80 mm
216-8120 — (1.567 inch) — A1 = A2 = A3 =
Reference
Ø 45.000 mm Ø 45.039 mm
293-2098 H8 A1 = A2 = A3 =
(1.7717 inch) (1.7732 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.
(2)
Limits and Fit Tolerances per ISO 286.

Reusability of Gearing
Accurate inspection is critical for the life of any gear. The maximum life of any drive train can be obtained through proper inspection and repair
procedures. If an unacceptable gear is reused, then there is a good possibility that the gear will fail. The gear that failed will destroy other components
in the drive train. The technician that is inspecting should be familiar with all types of gear wear and damage. The most common reasons for gear
failure are described in this guideline. Decisions regarding reuse and salvage of gears are aided in thorough inspections.

Note: Some gearing applications run in one direction. Thus wear should only occur on one side of the gear. If the inspection suggests that a gear is
worn, then flipping the gear may be an option thus using the other side of the tooth. Most likely application of gear flipping will be to those gears that
have symmetrical features.

Visual Inspections - Use the following general examples as a guide to inspect for the following common wear types, defects, critical part locations,
and features:

• Abrasive & Adhesive Wear

• Uneven Wear Patterns

• Corrosion

• Cracks

• Wear Steps

• Fretting

• Scoring, Dings, Dents, or Other Damage

Reference: SEBF8193 Reuse and Salvage Guidelines, "Reusability of Drive Train Gears" for more detailed information regarding general gear
inspection.

Reference: Channel1, "Gear Tooth Inspection" https://channel1.mediaspace.kaltura.com/media/Gear+Tooth+Inspection/1_5ujdi5zp for a video

representation of general gear inspection.

Dimensional Checks - Refer to the "Measurement Techniques" section before dimensional checks are performed. Refer to each components
illustration and table of dimensions and acceptable tolerances to inspect for excessive wear. In addition to these dimensional inspections, each part
must also pass one of the Non-Destructive Testing (NDT) methods listed in the "Crack Detection Methods" section.

Gear Inspection Examples

Illustration 16 g06085440

(A) Tooth Face

(B) Fillet Area

Check fillet area (B) with a seal pick. Fillet area (B) must be free from notches or s.

Note: If steps are found in the fillet area of a gear tooth, then DO NOT USE THE PART AGAIN.

Illustration 17 g03427659
Typical example of a gear inspection using reflective paper.

Utilize a clean, white piece of paper with a dull finish that to reflect light onto the face of each gear tooth during an inspection.

Illustration 18 g06085442
Illustration of view through eye piece of a pocket microscope.

If necessary use a microscope with light for enhanced view and to measure the defects. Refer to Tooling Table 3 for the part number.

Minor abrasive wear (C) may indicate that there is contamination in the gear case. Once the source of contamination has been found then, OK TO
USE PART AGAIN.

Illustration 19 g06033556

Typical example of a planetary gear with evidence of corrosion (D), OK TO USE THIS PART AGAIN.
(D) Corrosion

The presence of corrosion (D) may be due to contamination or as a result of the process used to clean the part. Identify the source of corrosion (D),
then OK TO USE PART AGAIN.

Illustration 20 g06033582
Typical example of spalling (E) on tooth face, DO NOT USE PART AGAIN.
(E) Spalling

Illustration 21 g06033587
Typical example of pitting (F) on tooth surface, DO NOT USE PART AGAIN.
(F) Pitting

Illustration 22 g03708114
Typical example of crack shown under Liquid Penetrant Testing (PT) of a gear, DO NOT USE THIS PART AGAIN. Refer to the "Liquid Penetrant Testing (PT)" section for
testing instructions.

Illustration 23 g06085444
Typical example of cracks found using Wet Magnetic Particle Testing (MT), DO NOT USE THIS PART AGAIN. Refer to the"Wet Magnetic Particle Testing (MT)" section for
testing instructions.

Planetary Gear Bore Inspections

Illustration 24 g03427695
Typical example of a planetary gear that requires further inspection of the bore.

Illustration 25 g06008970
Typical example of brinelling found during a planetary gear bore inspection, DO NOT USE THIS PART AGAIN.

Inspect planetary gear bore for pitting, heat cracks, and brinelling. If pitting, heat cracks, or brinelling are found on the planetary gear bore then, DO
NOT USE PART AGAIN.

Complete Steps 1 through 4 to inspect the planetary gear bore:

Illustration 26 g06026642
Typical example of cleaning a planetary gear bore. After cleaning a planetary gear bore, OK TO USE THIS PART AGAIN.
(G) Planetary gear bore before cleaning.
(H) Planetary gear bore after cleaning.

1. Clean the planetary gear bore thoroughly before inspecting.

Note: Planetary gear bores can be cleaned with cleaner for parts and a nonmetallic pad for rubbing that will not remove metal.

2. Visually inspect the planetary gear bore for damage and wear.

Note: An adequate light source is necessary to inspect planetary gear bore. An optical magnifier may also be used.

3. Inspect the planetary gear bore with a seal pick to detect any wear steps.

4. Perform Wet Magnetic Particle Testing (MT). Refer to the "Wet Magnetic Particle Testing (MT)"section for testing instructions.

Reusability of the Final Drive Planetary Gears

The planetary gears are heavily loaded in final drive. All gears must meet the given standards. Refer to Reuse and Salvage Guideline, SEBF8193,
"Reusability of Drive Train Gears" for additional information on final drive gears.

Planetary Gear Bore Reusability

Planetary gears with bores that function as a bearing outer race require special attention to the presence of corrosion or damage from foreign materials.

Extreme Pressure (EP) lubricants can cause corrosion. These lubricants are not recommended for use in Caterpillar final drives.

Check the bores of all planetary gears for other surface defects (cracks, pits, and so on).

Refer to Table 7 for the tolerances for reusability of the final drive planetary gear bores.

Illustration 27 g06322321
Typical example of stains on the surface of the gear bore.

If stains can be removed from the gear bore surface with reconditioning pad, USE THIS PART AGAIN.

If pitting are found in the stained areas, then DO NOT USE GEAR AGAIN.

Illustration 28 g06322341
Typical example of corrosion pitting on the gear bore. Due to surface pitting, DO NOT USE THIS PART AGAIN. The pitting will progress into spalling.

Illustration 29 g06322347
Wash board texture and appearance on surface of the gear bore is called "Brinelling", DO NOT USE THIS PART AGAIN.

Summary of Final Drive Planetary Gear Bore Tolerances

Illustration 30 g06318873
Typical example of planetary gear bore (D) measurement.
(D) Bore

Table 7
Record Actual Dimensions
Final Drive Planetary Gear Bore Tolerances Refer to the "Measurement Techniques" section for the proper techniques and
number of measurements to be taken.
Part
Tolerance
Number Measurement Measurement Measurement
(1) (D)

1V-8605
Ø 77.625 ± 0.013 mm (3.0561 ± 0.0005 inch) A1 = A2 = A3 =
9C-8074
2V-5710 A1 = A2 = A3 =
9C-8072
Ø 57.127 ± 0.01 mm (2.2491 ± 0.0004 inch)
9U-3124
186-4439

2V-5721 Ø 59.50 ± 0.25 mm (2.34252 ± 0.00984 inch) A1 = A2 = A3 =

3K-7020 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

3K-7110 Ø 43.218 ± 0.008 mm (1.7015 ± 0.0003 inch) A1 = A2 = A3 =

4D-1569 Ø 86.068 + 0.020 - 0.008 mm

A1 = A2 = A3 =
4E-0403 (3.3885 ± 0.0008 - 0.00031 inch)
4E-3638
Ø 112.44 ± 0.01 mm (4.4268 ± 0.0004 inch) A1 = A2 = A3 =
162-0191
4V-0093 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

4V-9867 Ø 124.663 ± 0.02 mm (4.9080 ± 0.0008 inch) A1 = A2 = A3 =

5K-4180 Ø 77.625 ± 0.013 mm (3.0561 ± 0.0005 inch) A1 = A2 = A3 =

5V-1480 Ø 75.86 ± 0.03 mm (2.9866 ± 0.0012 inch) A1 = A2 = A3 =

5V-4075 Ø 110.922 ± 0.025 mm (4.3670 ± 0.0010 inch) A1 = A2 = A3 =

5V-4699
Ø 124.663 ± 0.02 mm (4.9080 ± 0.0008 inch) A1 = A2 = A3 =
9U-3869
5V-8921 Ø 51.872 ± 0.010 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

6K-9129
Ø 41.303 ± 0.010 mm (1.6261 ± 0.0004 inch) A1 = A2 = A3 =
7K-7237
6S-3490 Ø 43.218 ± 0.008 mm (1.7015 ± 0.0003 inch) A1 = A2 = A3 =

6W-0299 Ø 193.794 ± 0.020 mm (7.6297 ± 0.0008 inch) A1 = A2 = A3 =

7G-2476 Ø 43.221 ± 0.008 mm (1.7016 ± 0.0003 inch) A1 = A2 = A3 =

7G-2486 Ø 43.221 ± 0.008 mm (1.7016 ± 0.0003 inch) A1 = A2 = A3 =

7G-3467 Ø 58.298 ± 0.01 mm (2.2952 ± 0.0004 inch) A1 = A2 = A3 =

7G-3468 Ø 66.274 ± 0.013 mm (2.6092 ± 0.0005 inch) A1 = A2 = A3 =

7G-3470 Ø 66.274 ± 0.013 mm (2.6092 ± 0.0005 inch) A1 = A2 = A3 =

71-4817 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

8K-0004 Ø 112.44 ± 0.01 mm (4.4268 ± 0.0004 inch) A1 = A2 = A3 =

8R-2199 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

8R-7812
Ø 43.218 ± 0.008 mm (1.7015 ± 0.0003 inch) A1 = A2 = A3 =
253-8920
8R-9750 Ø 112.44 ± 0.01 mm (4.4268 ± 0.0004 inch) A1 = A2 = A3 =

8R-9752 Ø 41.303 ± 0.010 mm (1.6261 ± 0.0004 inch) A1 = A2 = A3 =

9C-1528
Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =
147-1740

9C-5690 Ø 43.218 ± 0.008 mm (1.7015 ± 0.0003 inch) A1 = A2 = A3 =

9C-6032
Ø 57.536 ± 0.01 mm (2.2652 ± 0.0004 inch) A1 = A2 = A3 =
9U-2787

9C-6335 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

9C-7725
Ø 57.127 ± 0.01 mm (2.2491 ± 0.0004 inch) A1 = A2 = A3 =
164-3071
9G-1919 Ø 58.298 ± 0.01 mm (2.2952 ± 0.0004 inch) A1 = A2 = A3 =

9K-1758 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

9U-0972
Ø 77.625 ± 0.013 mm (3.0561 ± 0.0005 inch) A1 = A2 = A3 =
121-7583
9U-2974 A1 = A2 = A3 =
Ø 118.1 ± 0.02 mm (4.6496 ± 0.0008 inch)
152-1707
102-2454
Ø 66.274 ± 0.013 mm (2.6092 ± 0.0005 inch) A1 = A2 = A3 =
147-1206
105-8740 A1 = A2 = A3 =
Ø 75.0 ± 0.013 mm (2.9528 ± 0.0005 inch)
233-6995

108-8769 Ø 35.00 ± 0.010 mm (1.378 ± 0.0004 inch) A1 = A2 = A3 =

110-4799 A1 = A2 = A3 =
Ø 75.00 ± 0.013 mm (2.9528 ± 0.0005 inch)
159-8169
115-4878 Ø 112.776 ± 0.01 mm (4.4400 ± 0.0004 inch) A1 = A2 = A3 =

115-4880 Ø 140.0 ± 0.02 mm (5.5118 ± 0.0008 inch) A1 = A2 = A3 =

116-7712 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

127-9504 Ø 118.1 ± 0.02 mm (4.6496 ± 0.0008 inch) A1 = A2 = A3 =

129-4299 A1 = A2 = A3 =
Ø 92.267 ± 0.01 mm (3.6326 ± 0.0004 inch)
354-1306
118-3510
147-1759 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =
380-1599
173-9701 Ø 66.274 ± 0.01 mm (2.6092 ± 0.0004 inch) A1 = A2 = A3 =

180-0019 Ø 86.068 + 0.020 - 0.008 mm A1 = A2 = A3 =

261-1082 (3.3885 ± 0.0008 - 0.00031 inch)

187-3480 Ø 66.274 ± 0.01 mm (2.60921 ± 0.0004 inch) A1 = A2 = A3 =

192-0816
Ø 112.44 ± 0.01 mm (4.4268 ± 0.0004 inch) A1 = A2 = A3 =
237-0974
Ø 86.068 + 0.020 - 0.008 mm
208-7619 A1 = A2 = A3 =
(3.3885 ± 0.0008 - 0.00031 inch)

218-3172 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

221-8231 Ø 66.274 ± 0.013 mm (2.6092 ± 0.0005 inch) A1 = A2 = A3 =

245-3519 Ø 112.5 ± 0.02 mm (4.4291 ± 0.0008 inch) A1 = A2 = A3 =

245-3521 Ø 147.43 ± 0.02 mm (5.8043 ± 0.0008 inch) A1 = A2 = A3 =

271-2354 Ø 66.274 ± 0.013 mm (2.6092 ± 0.0005 inch) A1 = A2 = A3 =

281-9323 Ø 75.86 ± 0.03 mm (2.9866 ± 0.0012 inch) A1 = A2 = A3 =

281-9324 Ø 112.44 ± 0.01 mm (4.4268 ± 0.0004 inch) A1 = A2 = A3 =

325-5440 Ø 51.872 ± 0.01 mm (2.0422 ± 0.0004 inch) A1 = A2 = A3 =

361-8085 Ø 77.625 ± 0.013 mm (3.0561 ± 0.0005 inch) A1 = A2 = A3 =

364-3085 Ø 57.536 ± 0.01 mm (2.2652 ± 0.0004 inch) A1 = A2 = A3 =

388-2710 Ø 66.274 ± 0.01 mm (2.6092 ± 0.0004 inch) A1 = A2 = A3 =

391-8927 Ø 112.44 ± 0.01 mm (4.4268 ± 0.0004 inch) A1 = A2 = A3 =

417-1922 Ø 118.1 ± 0.013 mm (4.65 ± 0.0005 inch) A1 = A2 = A3 =

417-1924 Ø 140 ± 0.02 mm (5.5 ± 0.001 inch) A1 = A2 = A3 =

Ø 86.068 + 0.020 - 0.008 mm

469-1588 A1 = A2 = A3 =
(3.3885 ± 0.0008 - 0.00031 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Reusability of Planetary Shafts

Illustration 31 g06320721
Typical example of a slip fit shaft with minor fretting, OK TO USE THIS PART AGAIN.

Fretting may occur on the contact surface of the shaft and carrier. Shafts can be reused if less than 50% of the contact width and 25% of the shaft
diameter is affected. A shaft diameter in question should be measured and compared with the manufacturer's specifications.

Illustration 32 g06319268
Fretting on a planetary shaft.

If the shaft meets all other specifications, USE THIS PART AGAIN.

Refer to Table 8 for the dimensional tolerances for reusability of the planetary shaft.

Summary of the Planetary Shafts Tolerances

Illustration 33 g06318906
Typical example of planetary shaft measurements.
(E) Width
(F) Length

Table 8
Record Actual Dimensions
Planetary Shafts Tolerances Refer to the "Measurement Techniques" section for the
proper techniques and number of measurements to be taken.
Part
Width Tolerance Length Tolerance
Number Measurement Measurement Measurement
(1) (E) (F)

Ø 95.321 ± 0.01 mm 231.6 ± 0.5 mm

1V-6663 C1 = C2 = C3 =
(3.7528 ± 0.0004 inch) (9.12 ± 0.02 inch)
2D-6633
Ø 84.795 ± 0.008 mm 165.1 ± 0.5 mm
2G-6572 C1 = C2 = C3 =
(3.3384 ± 0.0003 inch) (6.50 ± 0.02 inch)
101-1505
2G-6571
Ø 59.380 ± 0.008 mm 162.6 ± 0.5 mm
3D-8416 C1 = C2 = C3 =
(2.3378 ± 0.0003 inch) (6.40 ± 0.02 inch)
101-1504
Ø 42.400 ± 0.006 mm 79.25 ± 0.25 mm
2P-4427 C1 = C2 = C3 =
(1.66929 ± 0.00024 inch) (3.12007 ± 0.00984 inch)
2V-1074 Ø 35.253 ± 0.008 mm 93.7 ± 0.5 mm
C1 = C2 = C3 =
5K-0927 (1.3879 ± 0.0003 inch) (3.69 ± 0.02 inch)
Ø 77.577 ± 0.010 mm 165.10 ± 0.5 mm
2V-4148 C1 = C2 = C3 =
(3.0542 ± 0.0004 inch) (6.500 ± 0.020 inch)
2V-5737 Ø 44.397 ± 0.008 mm 140 ± 1.0 mm
C1 = C2 = C3 =
186-4440 (1.7479 ± 0.0003 inch) (5.5 ± 0.04 inch)
2V-6220 Ø 42.316 ± 0.008 mm 109.2 ± 0.5 mm
C1 = C2 = C3 =
5K-1576 (1.6660 ± 0.0003 inch) (4.30 ± 0.02 inch)
2V-6221 Ø 42.316 ± 0.008 mm 127.0 ± 0.5 mm
C1 = C2 = C3 =
9K-1749 (1.6660 ± 0.0003 inch) (5.00 ± 0.02 inch)
Ø 35.255 ± 0.006 mm 76.2 ± 0.25 mm
3P-3242 C1 = C2 = C3 =
(1.3879 ± 0.0002 inch) (2.9999 ± 0.0098 inch)
Ø 47.193 ± 0.006 mm 80.3 ± 0.25 mm
3P-3246 C1 = C2 = C3 =
(1.8579 ± 0.0002 inch) (3.1614 ± 0.0098 inch)
Ø 95.321 ± 0.010 mm 222.5 ± 1.0 mm
4E-5870 C1 = C2 = C3 =
(3.7528 ± 0.0004 inch) (8.76 ± 0.04 inch)
Ø 42.316 ± 0.008 mm 91.5 ± 0.5 mm
4V-0094 C1 = C2 = C3 =
(1.6660 ± 0.0003 inch) (3.60 ± 0.02 inch)
4V-3009
5K-4178 Ø 52.316 ± 0.008 mm 145 ± 1.0 mm
C1 = C2 = C3 =
6W-7290 (2.0597 ± 0.0003 inch) (5.7 ± 0.04 inch)
9U-0786
Ø 47.193 ± 0.008 mm 162.5 ± 1.0 mm
4V-4501 C1 = C2 = C3 =
(1.8580 ± 0.0003 inch) (6.40 ± 0.04 inch)
Ø 42.316 ± 0.008 mm 112.0 ± 0.5 mm
4V-8534 C1 = C2 = C3 =
(1.6660 ± 0.0003 inch) (4.41 ± 0.02 inch)
4V-9577 Ø 31.742 ± 0.008 mm 80.0 ± 0.5 mm C1 = C2 = C3 =
6K-9062 (1.2497 ± 0.0003 inch) (3.15 ± 0.02 inch)
5V-4705
Ø 95.321 ± 0.010 mm 241 ± 1.0 mm
9V-6560 C1 = C2 = C3 =
(3.7528 ± 0.0004 inch) (9.5 ± 0.04 inch)
9V-8905

6P-6739 Ø 35.255 ± 0.006 mm 67.3 ± 0.5 mm C1 = C2 = C3 =

(1.3879 ± 0.0002 inch) (2.65 ± 0.02 inch)
Ø 35.255 ± 0.008 mm 73.9 ± 0.5 mm
6S-3771 C1 = C2 = C3 =
(1.3880 ± 0.0003 inch) (2.91 ± 0.02 inch)
Ø 42.395 ± 0.006 mm 80.3 ± 0.5 mm
8P-4047 C1 = C2 = C3 =
(1.6691 ± 0.0002 inch) (3.1614 ± 0.0197 inch)
Ø 47.193 ± 0.006 mm 109 ± 0.25 mm
8P-7241 C1 = C2 = C3 =
(1.8580 ± 0.0002 inch) (4.3 ± 0.010 inch)
Ø 35.253 ± 0.008 mm 83 ± 0.5 mm
8R-0248 C1 = C2 = C3 =
(1.3879 ± 0.0003 inch) (3.3 ± 0.02 inch)
Ø 44.397 ± 0.008 mm 111 ± 0.5 mm
8R-1888 C1 = C2 = C3 =
(1.7479 ± 0.0003 inch) (4.4 ± 0.02 inch)
Ø 42.316 ± 0.008 mm 99.0 ± 0.5 mm
8R-2200 C1 = C2 = C3 =
(1.6660 ± 0.0003 inch) (3.90 ± 0.02 inch)
Ø 47.981 ± 0.008 mm 120.5 ± 0.5 mm
8R-3252 C1 = C2 = C3 =
(1.8890 ± 0.0003 inch) (4.74 ± 0.02 inch)
Ø 77.577 ± 0.010 mm 151 ± 1.0 mm
8R-6933 C1 = C2 = C3 =
(3.0542 ± 0.0004 inch) (5.9 ± 0.04 inch)
Ø 120.00 ± 0.012 mm 254 ± 1.0 mm
8R-6937 C1 = C2 = C3 =
(4.7244 ± 0.0005 inch) (10.0 ± 0.04 inch)
Ø 77.577 ± 0.010 mm 169.7 ± 0.5 mm C1 = C2 = C3 =
8X-5689
(3.0542 ± 0.0004 inch) (6.68 ± 0.02 inch)
Ø 42.316 ± 0.008 mm 89.8 ± 0.5 mm
9C-6317 C1 = C2 = C3 =
(1.6660 ± 0.0003 inch) (3.54 ± 0.02 inch)
105-8748 Ø 59.38 ± 0.010 mm 142.7 ± 1.0 mm
C1 = C2 = C3 =
297-3030 (2.338 ± 0.0004 inch) (5.62 ± 0.04 inch)
Ø 47.193 ± 0.006 mm 150.5 ± 0.5 mm
105-9639 C1 = C2 = C3 =
(1.8580 ± 0.0002 inch) (5.93 ± 0.02 inch)
Ø 30 ± 0.008 mm 85 ± 0.5 mm
109-0292 C1 = C2 = C3 =
(1.2 ± 0.0003 inch) (3.3 ± 0.02 inch)
Ø 42.395 ± 0.006 mm 124.7 ± 0.5 mm
112-7309 C1 = C2 = C3 =
(1.6691 ± 0.0002 inch) (4.9094 ± 0.0197 inch)
Ø 70.029 ± 0.010 mm 103.3 ± 0.5 mm C1 = C2 = C3 =
129-4323
(2.7570 ± 0.0004 inch) (4.06692 ± 0.01969 inch)
Ø 47.193 ± 0.008 mm 162.5 ± 1.0 mm
190-3593 C1 = C2 = C3 =
(1.85799 ± 0.00031 inch) (6.39763 ± 0.03937 inch)
Ø 42.316 ± 0.008 mm 112.1 ± 1.0 mm
190-3594 C1 = C2 = C3 =
(1.6659 ± 0.0003 inch) (4.4134 ± 0.0394 inch)
Ø 42.3 ± 0.5 mm 94.5 ± 1.0 mm
190-5937 C1 = C2 = C3 =
(1.6654 ± 0.0197 inch) (3.7205 ± 0.0394 inch)
Ø 77.577 ± 0.010 mm 184.7 ± 0.5 mm
203-1817 C1 = C2 = C3 =
(3.0542 ± 0.0004 inch) (7.27 ± 0.02 inch)
223-5836 Ø 77.577 ± 0.010 mm 180.5 ± 0.5 mm
C1 = C2 = C3 =
297-3031 (3.0542 ± 0.0004 inch) (7.11 ± 0.02 inch)
Ø 77.58 ± 0.010 mm 115 ± 1.0 mm
245-5946 C1 = C2 = C3 =
(3.0543 ± 0.0004 inch) (4.5 ± 0.04 inch)
Ø 110 ± 0.012 mm 232 ± 1.0 mm
245-5947 C1 = C2 = C3 =
(4.3 ± 0.0005 inch) (9.1 ± 0.04 inch)
Ø 52.99 ± 0.008 mm 90.5 ± 0.5 mm
270-9307 C1 = C2 = C3 =
(2.086 ± 0.0003 inch) (3.56 ± 0.02 inch)
Ø 95.321 ± 0.01 mm 208.8 ± 1.0 mm
297-3032 C1 = C2 = C3 =
(3.7528 ± 0.0004 inch) (8.22 ± 0.04 inch)
Ø 42.316 ± 0.008 mm 97 ± 0.5 mm C1 = C2 = C3 =
327-2243
(1.6660 ± 0.0003 inch) (3.8 ± 0.02 inch)
Ø 59.38 ± 0.010 mm 111.5 ± 0.5 mm
361-8065 C1 = C2 = C3 =
(2.338 ± 0.0004 inch) (4.39 ± 0.02 inch)
Ø 44.397 ± 0.008 mm 102.5 ± 0.5 mm
366-5768 C1 = C2 = C3 =
(1.7479 ± 0.00031 inch) (4.04 ± 0.02 inch)
369-7660 C1 = C2 = C3 =

Ø 59.38 ± 0.010 mm 142.7 ± 0.5 mm

(2.338 ± 0.0004 inch) (5.62 ± 0.02 inch)
Ø 47.193 ± 0.006 mm 165.0 ± 0.25 mm
388-2711 C1 = C2 = C3 =
(1.8580 ± 0.0002 inch) (6.4961 ± 0.0098 inch)
Ø 95.321 ± 0.010 mm 169 ± 1 mm
419-6356 C1 = C2 = C3 =
(3.7528 ± 0.0004 inch) (6.7 ± 0.04 inch)
Ø 120 ± 0.012 mm 287 ± 1 mm
419-6357 C1 = C2 = C3 =
(4.7 ± 0.0005 inch) (11.3 ± 0.04 inch)
Ø 59.38 ± 0.010 mm 142.7 ± 0.5 mm
460-1456 C1 = C2 = C3 =
(2.3378 ± 0.0004 inch) (5.62 ± 0.02 inch)
Ø 95.321 ± 0.010 mm 208.8 ± 1.0 mm
468-4042 C1 = C2 = C3 =
(3.7528 ± 0.0004 inch) (8.22 ± 0.04 inch)
Ø 77.577 ± 0.010 mm 180.5 ± 0.5 mm
468-4044 C1 = C2 = C3 =
(3.0542 ± 0.0004 inch) (7.11 ± 0.02 inch)
Ø 77.577 ± 0.010 mm 186.8 ± 0.5 mm
468-4045 C1 = C2 = C3 =
(3.0542 ± 0.0004 inch) (7.35 ± 0.02 inch)
Ø 59.38 ± 0.01 mm
469-1589 152.0 mm (5.9842 inch) C1 = C2 = C3 =
(2.3378 ± 0.0004 inch)
Ø 59.38 + 0.010 - 0.00 mm 142.7 ± 0.5 mm
470-0922 C1 = C2 = C3 =
(2.338 + 0.0004 - 0.000 inch) (5.62 ± 0.02 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Illustration 34 g06369426
Typical example of planetary shaft measurement of part number 215-7488.

Table 9
Record Actual Dimensions
Planetary Shafts Tolerances
Refer to the "Measurement Techniques" section for the proper techniques and
Part Number 215-7488
number of measurements to be taken.
Location Minimum Maximum Measurement Measurement Measurement
78.0 mm 78.2 mm
G C1 = C2 = C3 =
(3.07086 inch) (3.07873 inch)
30.0 mm 30.05 mm
H C1 = C2 = C3 =
(1.18110 inch) (1.18307 inch)
25.6 mm 25.7 mm
J C1 = C2 = C3 =
(1.00787 inch) (1.01181 inch)
7.5 mm 8.5 mm
K C1 = C2 = C3 =
(0.29528 inch) (0.33465 inch)
Ø 45.33 mm Ø 45.35 mm
L C1 = C2 = C3 =
(1.78464 inch) (1.78543 inch)
Ø 45.3 mm Ø 45.5 mm
M C1 = C2 = C3 =
(1.78346 inch) (1.79134 inch)
Ø 44.9 mm Ø 44.95 mm
N C1 = C2 = C3 =
(1.76771 inch) (1.76968 inch)
Ø 39.989 mm Ø 40.000 mm
P C1 = C2 = C3 =
(1.57437 inch) (1.57480 inch)
Ø 34.85 mm Ø 35.0 mm
R C1 = C2 = C3 =
(1.37204 inch) (1.37795 inch)

Illustration 35 g06369452
Typical example of planetary shaft measurement of part number 215-8060.

Table 10
Record Actual Dimensions
Planetary Shafts Tolerances
Refer to the "Measurement Techniques" section for the proper techniques and number of
Part Number 215-8060
measurements to be taken.
Location Minimum Maximum Measurement Measurement Measurement
39.95 mm
S Reference C1 = C2 = C3 =
(1.573 inch)
39.8 mm
T Reference C1 = C2 = C3 =
(1.57 inch)
72.3 mm
U Reference C1 = C2 = C3 =
(2.85 inch)

Final Drive Spindle Spline and Hub Reusability

General Guidelines for Inspection of Splines

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

Always use proper lifting devices for the safety of the operator and to prevent damage to the machined surface. Personal protective Equipment (PPE)
should be worn always for the operator's protection.

Signs of Potential Failure

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

There are two typical signs of failure:

• Spline wear or fracture from misalignment

• Cracking from fatigue which could lead to fracture

Spline Wear and Misalignment

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

There is normally a small amount of relative motion between mating spline teeth. Uneven contact patterns on teeth of the splines are the result of
misalignment of one or both of the mating splines. The spline teeth will not fully engage if the teeth are misaligned. This means that only a portion of
each tooth is carrying the full load. Misalignment of teeth causes high contact pressures on the portion of the tooth that carries the load. The damage
on the surface that is caused by these conditions is spline wear and fretting. Misalignment can be identified by the uneven contact pattern on the spline
teeth.

Misalignment of the spline can be caused by worn bearings, damaged bearings, bores of the carrier, faces of the carrier, or shafts. If any spline
displays uneven contact patterns, be sure to check for misalignment and correct the problem.

Misaligned splines can be reused if the splines meet the specifications for reusability.

Cracks on Spline Teeth from Fatigue

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

Visual Inspection

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

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

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

Illustration 36 g01716065
Typical example of check spline for wear steps with a seal pick.

If the splines stop the seal pick on the worn area, measure the splines before reusing. Generally, a 0.203 mm (0.0080 inch) wear step will stop a seal
pick.

Typically spline can be reused if step measures less than 0.203 mm (0.0080 inch)

Visual Examples of Spline

Normal Wear

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

Wear Steps

Illustration 37 g06122439
Typical example of an internal spline with significant wear (L) steps, DO NOT USE AGAIN.
(L) Wear

Illustration 38 g06319105

Check the ends of location of the engagement of the splines.

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

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

Corrosion and Pitting

Illustration 39 g06324680
Typical example of corrosion from poor storage techniques, clean inspect for pitting. If excessive pitting, then DO NOT USE THIS PART AGAIN.

Damage to Teeth

Illustration 40 g06324678
Typical example of spline damage from poor handling, but no signs of cracking. Use a polishing stone to smooth any raised material from the indentation, OK TO USE THIS
PART AGAIN.

Illustration 41 g06324674
Typical example of spline damage from poor handling with a sign of cracking. Use a polishing stone to smooth any raised material from the indentation. If evidence of crack after
removal of raised material, then DO NOT USE THIS PART AGAIN.

Crack from Fatigue on Spindles

Illustration 42 g06324684
Typical example of a crack extending from the spline into the bolt hole. The bolt hole is weakened and premature failure will result, DO NOT USE THIS PART AGAIN.

Illustration 43 g06324686
Typical example of a crack in the root of the spline tooth, DO NOT USE THIS PART AGAIN.

Spline Wear Measurement Procedures

Internal Spline

Illustration 44 g06321306
Typical wear step on an internal spline.

Illustration 45 g06075213
Typical example of taking an internal spline measurement.

Illustration 46 g06181320
(G) 1, (G) 2, and (G) 3 Measurement Locations

The location of the gage pins at 60° intervals is critical to the formula. These three locations will provide information about the wear of the part. Refer
to Illustration 46.

An inside micrometer must be positioned to measure the shortest distance points on the gage pins. This procedure will provide the measurement of the
wear on the spline. The gage pin diameter for each individual part is determined by the size and pitch of the spline.

Calculate the average of the values taken from locations (G) 1, (G) 2, and (G) 3. The difference between the measurements will determine if there is an
out of round condition caused by poor load distribution on the splines.

Place gage pins at 60° intervals on the planetary carrier. The location of the gage pins at 60° intervals is critical to the formula. These three locations
will provide information about the wear of the part.

Steps 1 through 4 demonstrate an example of the process to calculation internal spline roundness. Provided is an example of performing spline
reusability calculations of a reaction hub part number 137-8628 for a 994 wheel loader. Refer to Table 21 for specifications:

1. Take measurements at locations (G) 1, (G) 2, and (G) 3 between gage pins. Taken measurements are recorded in Table 11.

Table 11
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Recording 3 Measurements Taken
Location Measurements Taken
G1 Ø 465.505 mm (18.3269 inch)
G2 Ø 465.620 mm (18.3315 inch)
G3 Ø 466.180 mm (18.3535 inch)

2. Add the measurements together to calculate the sum. The sum of the three measurements is 1397.305 mm (55.0119 inch).

Table 12
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Calculating Sum of 3 Measurements Taken
Measurement
Calculation SUM Total =
Locations

G1, G2, and G3 G1 + G2 + G3 1397.305 mm (55.0119 inch)

3. Divide the sum of the measurements taken by 3 to calculate the average. The calculated average of 465.768 mm (18.3373 inch) is less than the
reusability specification of 465.843 mm (18.3402 inch). In this example the internal spline is within the reusability specification and therefore
passes this test, proceed to Step 4.

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

Table 13
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Calculating Average of the 3 Measurements Taken
Location Calculations Results
(G1 + G2 + G3) / 3
G1, G2, and G3 Ø 465.768 mm (18.3373 inch)
= Avg
Refer to Specifications in Reusability
Ø 465.843 mm (18.3402 inch)
Table 21. Specification
Avg > Reusability
Avg = Ø 465.768 mm (18.3373 inch) < than Reusability Specification of
Specification = Fail
Avg Specification Ø 465.843 mm (18.3402 inch)
Avg < Reusability
Pass
Specification = Pass

4. The difference between the high measurement and the low measurement determines if the spline is round. Out-of-round or ovality can cause
uneven load distribution on the splines. Calculate the difference between the high and the low measurement by subtracting the high
measurement of Ø 466.180 mm (18.3535 inch) from the low measurement of Ø 465.505 mm (18.3269 inch). The difference between the high
and low measurements determine if the spindle can be reused. The difference in this example is 0.675 mm (0.0266 inch).

Maximum difference between the high measurement and the low measurement allowance of 0.67 mm (0.027 inch) and the actual difference of
0.675 mm (0.0266 inch) is greater than the allowable maximum difference.

If the maximum difference between the high measurement and the low measurement is greater than 0.67 mm (0.027 inch) the internal spline is
considered to be out-of-round or oval shaped and not reusable, DO NOT USE THE PART AGAIN.

Table 14
994 Wheel Loader Reaction Hub (137-8628) Internal Spline
Example of Determining the Difference from the 2 Measurements Taken
Location Calculations Results
G1 Low Ø 465.505 mm (18.3269 inch)
G3 High Ø 466.180 mm (18.3535 inch)
High and Low
G3 - G1 0.675 mm (0.0266 inch)
Difference =
Maximum
Refer to Specifications in Table 21. Difference 0.67 mm (0.027 inch)
Allowance
Actual Difference < Maximum
Actual Difference = 0.675 mm (0.0266 inch) < than
Actual Difference (H - L) Maximum Difference Allowance = Fail
Maximum Difference Allowance of 0.67 mm (0.027 inch)
Difference Allowance Actual Difference > Maximum
Fail
Difference Allowance = Pass

External Spline

Illustration 47 g06321303
Typical wear step on an external spline.

Illustration 48 g06322365
Typical example of using a straight edge to measure a wear step on a spline tooth.

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

Illustration 49 g01716121
Typical example of a wear step. A 0.152 mm (0.0060 inch) wear step is required to stop a seal pick. If the wear step is greater than 0.203 mm (0.0080 inch), then DO NOT USE
THE PART AGAIN.

Illustration 50 g06075290
Typical example of taking a Measurement Over Pins (MOP).

Illustration 51 g06181327
(L) 1, (L) 2, and (L) 3 Measurement Locations

The location of gage pins at 60° intervals is critical to the formula. These three locations will provide information about the wear of the part. Refer to
Illustration 51.

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

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

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

Steps 1 through 4 demonstrate an example of the process to calculation external spline roundness. Provided is an example of performing spline
reusability calculations of a spindle part number 131-1296 for a 990 Series II wheel loader.

NOTICE

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

1. Take measurements at locations (L) 1, (L) 2, and (L) 3 over gage pins. Taken measurements are recorded in Table 15.

Table 15
990 Series II Wheel Loader Spindle (131-1296) External Spline
Example of Recording 3 Measurements Taken
Location Measurements Taken
L1 Ø 299.525 mm (11.7923 inch)
L2 Ø 298.950 mm (11.7696 inch)
L3 Ø 298.895 mm (11.7675 inch)

2. Add the measurements together to calculate the sum. The sum of the three measurements is 897.370 mm (35.3295 inch).

Table 16
990 Series II Wheel Loader Spindle (131-1296) External Spline
Example of Calculating Sum of 3 Measurements Taken
Measurement
Calculation SUM Total =
Locations
L1, L2, and L3 L1 + L2 + L3 897.370 mm (35.3295 inch)

3. Divide the sum of the measurements taken by 3 to calculate the average. The calculated average of 299.123 mm (11.77647 inch) is greater than
the reusability specification of Ø 298.9818 mm (11.77091 inch). In this example the external spline is within the reusability specification and
therefore passes this test, proceed to Step 4.

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

Table 17
990 Series II Wheel Loader Spindle (131-1296) External Spline
Example of Calculating the Average of 3 Measurements Taken
Location Calculations Results
(L1 + L2 + L3) / 3
L1, L2, and L3 299.123 mm (11.77647 inch)
= Avg
Refer to Specifications in Reusability
Ø 298.9818 mm (11.77091 inch)
Table 19. Specification
Avg < Reusability
Avg = 299.123 mm (11.77647 inch) > than Reusability Specification of
Specification = Fail
Avg Specification Ø 298.9818 mm (11.77091 inch)
Avg > Reusability
Pass
Specification = Pass

4. The difference between the high measurement and the low measurement determines if the spline is round. Out-of-round or ovality can cause
uneven load distribution on the splines. Calculate the difference between the high and the low measurement by subtracting the high
measurement of Ø 299.525 mm (11.7923 inch) from the low measurement of Ø 298.895 mm (11.7675 inch). The difference between the high
and low measurement determine if the spindle can be reused. The difference in this example is 0.630 mm (0.0248 inch).

Maximum difference between the high measurement and the low measurement allowance of 0.70 mm (0.028 inch) and the actual difference of
0.630 mm (0.0248 inch) is less than the allowable maximum difference.

If the maximum difference between the high measurement and the low measurement is greater than 0.70 mm (0.028 inch) the external spline is
considered to be out-of-round or oval shaped and not reusable, DO NOT USE THE PART AGAIN.

Table 18
990 Series II Wheel Loader Spindle (131-1296) External Spline
Example of Determining the Difference from the 3 Measurements Taken
Location Calculations Results

L1 High Ø 299.525 mm (11.7923 inch)

L3 Low Ø 298.895 mm (11.7675 inch)

High and Low
L1 - L3 0.630 mm (0.0248 inch)
Difference =
Maximum
Refer to Specifications in 19. Difference 0.70 mm (0.028 inch)
Allowance
Actual Difference > Maximum
Actual Difference = 0.630 mm (0.0248 inch) < than
Actual Difference (H - L) Maximum Difference Allowance = Fail
Maximum Difference Allowance of 0.70 mm (0.028 inch)
Difference Allowance Actual Difference < Maximum
Pass
Difference Allowance = Pass

Methods of Securing Gage Pins

Illustration 52 g06075262
Typical example of MOP.
(N) Rubber Band
(P) Gage Pins

Note: Rubber band (N) can be used to secure gage pins (P) in place when taking measurements of external splines. Refer to Illustration 52.

Illustration 53 g06124082
Typical example of a magnetizer/ demagnetizer.

NOTICE

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

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

Spline Summary of Dimensions for Reusability

Illustration 54 g06321299
Typical example of taking a Measurement Over Pins (MOP) (A) of spindle spline.
(A) Measurement Over Pins (MOP)

Table 19
Record Actual Dimensions
Refer to the "Measurement Techniques"
Spindle Spline Dimensions and Tolerances
section for the proper techniques and
number of measurements to be taken.
Original Reusability Maximum
Part
Gage Pin Specification Specification Difference
Number Measurement
(1) Diameter Measurement Over Measurement Over High and Low
Gage Pins Gage Pins Measurement
Ø 6.3500 mm Ø 140.0861 mm Ø 140.0268 mm 0.0593 mm L1 =
1V-1317
(0.25000 inch) (5.51519 inch) (5.51285 inch) (0.00234 inch)
1V-1379 Ø 6.3500 mm Ø 121.0081 mm Ø 120.9527 mm 0.0554 mm L1 =
4K-6388 (0.25000 inch) (4.76409 inch) (4.76191 inch) (0.00218 inch)
1V-1392 L1 =
Ø 6.3500 mm Ø 120.8811 mm Ø 120.8256 mm 0.0555 mm
2V-5132
(0.25000 inch) (4.75909 inch) (4.75690 inch) (0.00219 inch)
7K-1138
1V-1554 L1 =
Ø 3.9675 mm Ø 88.4022 mm Ø 88.3458 mm 0.0564 mm
6K-8848
(0.15620 inch) (3.48039 inch) (3.47817 inch) (0.00222 inch)
7K-7468
1V-4718 L1 =
Ø 6.3500 mm Ø 98.7222 mm Ø 98.6713 mm 0.0509 mm
6K-5836
(0.25000 inch) (3.88669 inch) (3.88469 inch) (0.00200 inch)
7K-7459
Ø 4.7625 mm Ø 169.6212 mm Ø 169.5507 mm 0.0705 mm L1 =
1V-4975
(0.18750 inch) (6.67799 inch) (6.67521 inch) (0.00278 inch)
Ø 6.3500 mm Ø 140.0860 mm Ø 140.0267 mm 0.0593 mm L1 =
3Q-6136
(0.25000 inch) (5.51519 inch) (5.51285 inch) (0.00234 inch)
3V-2478 L1 =
Ø 4.7625 mm Ø 258.374 mm Ø 258.2842 mm 0.0897 mm
5V-7635
(0.18750 inch) (10.17218 inch) (10.16865 inch) (0.00353 inch)
6W-7271
Ø 6.3500 mm Ø 98.722 mm Ø 98.67113 mm 0.05097 mm L1 =
3Y-4071
(0.25000 inch) (3.8867 inch) (3.88468 inch) (0.00200 inch)
Ø 6.3500 mm Ø 121.076 mm Ø 120.0207 mm 0.0553 mm L1 =
3Y-5779
(0.25000 inch) (4.7668 inch) (4.72522 inch) (0.00218 inch)
3Y-7724 L1 =
Ø 3.9675 mm Ø 88.402 mm Ø 88.3456 mm 0.0564 mm
4V-9580
(0.15620 inch) (3.4804 inch) (3.47817 inch) (0.00222 inch)
9C-2312
4V-5213 Ø 6.3500 mm Ø 124.299 mm Ø 124.2429 mm 0.0561 mm L1 =
9C-0616 (0.25000 inch) (4.8937 inch) (4.89144 inch) (0.00221 inch)
4V-9822 L1 =
Ø 2.3825 mm Ø 77.112 mm Ø 77.0446 mm 0.0674 mm
4Y-0984
(0.09380 inch) (3.0359 inch) (3.03325 inch) (0.00265 inch)
9C-2313
Ø 6.3500 mm Ø 121.0081 mm Ø 120.9527 mm 0.0554 mm L1 =
5K-1651
(0.25000 inch) (4.76409 inch) (4.76191 inch) (0.00218 inch)
Ø 6.3500 mm Ø 124.299 mm Ø 124.2429 mm 0.0561 mm L1 =
(0.25000 inch) (4.8937 inch) (4.89144 inch) (0.00221 inch)

5V-4062
9C-0615
138-4805
Ø 6.3500 mm Ø 120.881 mm Ø 120.8255 mm 0.0555 mm L1 =
5V-5692
(0.25000 inch) (4.7591 inch) (4.75690 inch) (0.00219 inch)
Ø 3.9675 mm Ø 88.4020 mm Ø 88.3456 mm 0.0564 mm L1 =
6S-3012
(0.15620 inch) (3.48039 inch) (3.47817 inch) (0.00222 inch)
Ø 4.7625 mm Ø 299.080 mm Ø 298.9818 mm 0.0982 mm L1 =
6W-7349
(0.18750 inch) (11.7748 inch) (11.77091 inch) (0.00387 inch)
Ø 4.763 mm Ø 169.545 mm Ø 169.4744 mm 0.0706 mm L1 =
7K-3737
(0.1875 inch) (6.6750 inch) (6.67221 inch) (0.00278 inch)
Ø 6.3500 mm Ø 140.086 mm Ø 140.0267 mm 0.0593 mm L1 =
7U-0774
(0.25000 inch) (5.5152 inch) (5.51285 inch) (0.00234 inch)
7V-8640 Ø 6.3500 mm Ø 124.371 mm Ø 124.3150 mm 0.0560 mm L1 =
9C-2310 (0.25000 inch) (4.8965 inch) (4.89428 inch) (0.00221 inch)
Ø 4.7625 mm Ø 207.6679 mm Ø 207.5892 mm 0.0787 mm L1 =
8K-6574
(0.18750 inch) (8.17589 inch) (8.17279 inch) (0.00310 inch)
Ø 4.7625 mm Ø 169.545 mm Ø 169.4744 mm 0.0706 mm L1 =
8K-6929
(0.18750 inch) (6.6750 inch) (6.67221 inch) (0.00278 inch)
Ø 4.8768 mm Ø 207.9219 mm Ø 207.8434 mm 0.0785 mm L1 =
8S-4173
(0.19200 inch) (8.18589 inch) (8.18279 inch) (0.00309 inch)
Ø 6.3500 mm Ø 140.086 mm Ø 140.0267 mm 0.0593 mm L1 =
8V-6388
(0.25000 inch) (5.5152 inch) (5.51285 inch) (0.00234 inch)
9C-1639 Ø 6.3500 mm Ø 121.008 mm Ø 120.9526 mm 0.0554 mm L1 =
138-4804 (0.25000 inch) (4.7641 inch) (4.76191 inch) (0.00218 inch)
Ø 6.3500 mm Ø 121.0081 mm Ø 120.9527 mm 0.0554 mm
9K-4966 L1 =
(0.25000 inch) (4.76409 inch) (4.76191 inch) (0.00218 inch)
9Q-5379 Ø 4.7630 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
388-4764 (0.18752 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)
Ø 4.762 mm Ø 169.545 mm Ø 169.4744 mm 0.0706 mm
9V-1330 L1 =
(0.1875 inch) (6.6750 inch) (6.67221 inch) (0.00278 inch)
Ø 4.7625 mm Ø 299.080 mm Ø 298.9818 mm 0.0982 mm L1 =
116-6260
(0.18750 inch) (11.7748 inch) (11.77091 inch) (0.00387 inch)
Ø 4.7625 mm Ø 299.080 mm Ø 298.9818 mm 0.0982 mm L1 =
131-1296
(0.18750 inch) (11.7748 inch) (11.77091 inch) (0.00387 inch)
135-7742 Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
417-0990 (0.18750 inch) (6.678 inch) (6.67520 inch) (0.00278 inch)
Ø 4.7625 mm Ø 481.993 mm Ø 481.8563 mm 0.1367 mm L1 =
137-8627
(0.18750 inch) (18.9761 inch) (18.97068 inch) (0.00538 inch)
142-7562 Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
197-8287 (0.18750 inch) (6.678 inch) (6.67520 inch) (0.00278 inch)
Ø 4.7625 mm Ø 190.017 mm Ø 189.9422 mm 0.0749 mm L1 =
147-6457
(0.18750 inch) (7.4810 inch) (7.47802 inch) (0.00295 inch)
151-3036 Ø 4.7625 mm Ø 190.017 mm Ø 189.9422 mm 0.0749 mm L1 =
489-3400 (0.18750 inch) (7.481 inch) (7.47802 inch) (0.00295 inch)
180-0017 Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
392-7976 (0.18750 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)
205-0747 Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
482-1805 (0.18750 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)
Ø 4.0005 mm Ø 347.502 mm Ø 347.3916 mm 0.1104 mm L1 =
244-1095
(0.1575 inch) (13.6812 inch) (13.67681 inch) (0.00435 inch)
Ø 6.3500 mm Ø 124.299 mm Ø 124.2429 mm 0.0561 mm L1 =
267-7538
(0.25000 inch) (4.8937 inch) (4.89144 inch) (0.00221 inch)
Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
353-8391
(0.18750 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)
Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
382-0663
(0.18750 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)
Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm
417-0990 L1 =
(0.18750 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)

419-6350 Ø 4.7625 mm Ø 481.993 mm Ø 481.8563 mm 0.1367 mm L1 =

(0.18750 inch) (18.9761 inch) (18.97068 inch) (0.00538 inch)
Ø 4.7625 mm Ø 169.621 mm Ø 169.5505 mm 0.0705 mm L1 =
434-3964
(0.18750 inch) (6.6780 inch) (6.67520 inch) (0.00278 inch)
Ø 4.7625 mm Ø 190.017 mm Ø 189.9422 mm 0.0749 mm
469-1579 L1 =
(0.18750 inch) (7.481 inch) (7.47802 inch) (0.00295 inch)
Ø 6.3500 mm Ø 124.299 mm Ø 124.2429 mm 0.0561 mm
495-8242 L1 =
(0.25000 inch) (4.8937 inch) (4.89144 inch) (0.00221 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Illustration 55 g06321308
Typical example of taking a measurement between pins (B) of a reaction hub spline.
(B) Measurement Between Pins

Table 20
Record Actual Dimensions
Refer to the "Measurement
Techniques" section for the
Internal Reaction Hub Spline Dimensions and Tolerances
proper techniques and
number of measurements to
be taken.
Original Reusability
Assembly Maximum
Specification Specification
Part Part Gage Pin Difference
Measurement Measurement Measurement
Number Number (1) Diameter High and Low
(1) Between Gage Between Gage
Measurement
Pins Pins
1C-7312 1C-7101 G1 =
Ø 4.877 mm Ø 154.955 mm Ø 155.0332 mm 0.0782 mm
317-4581 317-4580
(0.1920 inch) (6.1006 inch) (6.10366 inch) (0.00308 inch)
463-9549 463-9547
Ø 6.3500 mm Ø 119.642 mm Ø 119.7143 mm 0.0723 mm G1 =
1V-8610 1V-8608
(0.25000 inch) (4.7103 inch) (4.71315 inch) (0.00285 inch)
Ø 6.3500 mm Ø 103.817 mm Ø 103.8876 mm 0.0706 mm G1 =
2V-5711 2V-5712
(0.25000 inch) (4.0873 inch) (4.09005 inch) (0.00278 inch)
4D-7614 Ø 4.8768 mm Ø 193.050 mm Ø 193.1355 mm 0.0855 mm G1 =
—
6G-6874 (0.19200 inch) (7.6004 inch) (7.60375 inch) (0.00337 inch)
Ø 6.3500 mm Ø 100.524 mm Ø 100.5942 mm 0.0702 mm
4V-0092 175-7527 G1 =
(0.25000 inch) (3.9576 inch) (3.96039 inch) (0.00276 inch)
Ø 6.000 mm Ø 104.953 mm Ø 105.0215 mm 0.0685 mm
4V-8535 162-9389 G1 =
(0.2362 inch) (4.1320 inch) (4.13469 inch) (0.00269 inch)
Ø 2.3825 mm Ø 70.0910 mm Ø 70.1662 mm 0.0752 mm G1 =
4V-9820 4V-9818
(0.09380 inch) (2.75948 inch) (2.76244 inch) (0.00296 inch)
5K-4408 5K-4271 Ø 6.3500 mm Ø 119.6416 mm Ø 119.7139 mm 0.0723 mm G1 =
7K-7462 7K-7463 (0.25000 inch) (4.71029 inch) (4.71314 inch) (0.00285 inch)
5V-4702 Ø 5.4864 mm Ø 242.014 mm Ø 242.1114 mm 0.0974 mm G1 =
—
5V-8974 6W-7272 (0.21600 inch) (9.5281 inch) (9.53192 inch) (0.00383 inch)
5V-9356 Ø 4.0640 mm Ø 76.104 mm Ø 76.1714 mm 0.0674 mm G1 =
5V-9355
9C-9187 (0.16000 inch) (2.9962 inch) (2.99887 inch) (0.00265 inch)
6K-0461 6K-0462 G1 =
Ø 6.3500 mm Ø 78.3082 mm Ø 78.3773 mm 0.0691 mm
7K-7432 7K-7435
(0.25000 inch) (3.08299 inch) (3.08571 inch) (0.00272 inch)
9C-7457 9C-2975
Ø 4.0640 mm Ø 76.1035 mm Ø 76.1708 mm 0.0674 mm G1 =
6S-7803 6S-3013
(0.16000 inch) (2.99619 inch) (2.99885 inch) (0.00265 inch)
Ø 5.4864 mm Ø 282.692 mm Ø 282.7974 mm 0.1054 mm G1 =
— 6W-7351
(0.21600 inch) (11.1296 inch) (11.13374 inch) (0.00415 inch)
7K-0454 7K-0253 Ø 4.0640 mm Ø 76.1035 mm Ø 76.1708 mm 0.0674 mm G1 =
7K-7431 7K-7434 (0.16000 inch) (2.99619 inch) (2.99885 inch) (0.00265 inch)
Ø 6.3500 mm Ø 100.523 mm Ø 100.5932 mm 0.0702 mm
7K-7433 7K-7436 G1 =
(0.25000 inch) (3.95759 inch) (3.96035 inch) (0.00276 inch)
Ø 4.877 mm Ø 154.955 mm Ø 155.0332 mm 0.0782 mm
8K-0068 9K-0101 G1 =
(0.1920 inch) (6.1006 inch) (6.10366 inch) (0.00308 inch)

— 8P-3133 Ø 3.1750 mm Ø 120.310 mm Ø 120.4010 mm 0.091 mm G1 =

(0.12500 inch) (4.73660 inch) (4.74019 inch) (0.00358 inch)
Ø 6.3500 mm Ø 119.642 mm Ø 119.7143 mm Ø 0.0723 mm G1 =
8V-6382 8V-6387
(0.25000 inch) (4.7103 inch) (4.71315 inch) (0.00285 inch)
9C-4811 9C-4812 Ø 6.3500 mm Ø 100.523 mm Ø 100.5932 mm 0.0702 mm
G1 =
9K-2300 9K-1852 (0.25000 inch) (3.9576 inch) (3.96035 inch) (0.00276 inch)
Ø 6.3500 mm Ø 103.817 mm Ø 103.8876 mm 0.0706 mm
9C-5852 9C-5851 G1 =
(0.25000 inch) (4.0873 inch) (4.09005 inch) (0.00278 inch)
Ø 6.3500 mm Ø 119.642 mm Ø 119.7143 mm 0.0723 mm G1 =
9U-0975 9U-0976
(0.25000 inch) (4.7103 inch) (4.71315 inch) (0.00285 inch)
Ø 5.4864 mm Ø 282.692 mm Ø 282.7974 mm 0.1054 mm G1 =
— 9U-3391
(0.2160 inch) (11.1296 inch) (11.13374 inch) (0.00415 inch)
Ø 3.175 mm Ø 90.137 mm Ø 90.505 mm 0.3680 mm
9W-2977 9W-2976 G1 =
(0.1250 inch) (3.5487 inch) (3.5632 inch) (0.0145 inch)
Ø 5.000 mm Ø 154.572 mm Ø 154.6507 mm 0.0787 mm
110-0551 105-8714 G1 =
(0.19685 inch) (6.08550 inch) (6.08860 inch) (0.00310 inch)
Ø 4.877 mm Ø 154.955 mm Ø 155.0332 mm 0.0782 mm
110-0552 105-8715 G1 =
(0.1920 inch) (6.1006 inch) (6.10366 inch) (0.00308 inch)
Ø 5.4864 mm Ø 282.692 mm Ø 282.7974 mm 0.1054 mm G1 =
— 107-0691
(0.21600 inch) (11.1296 inch) (11.13374 inch) (0.00415 inch)
118-9399 118-9400 Ø 4.877 mm Ø 154.955 mm Ø 155.0332 mm 0.0782 mm G1 =
162-0193 162-0194 (0.1920 inch) (6.1006 inch) (6.10366 inch) (0.00308 inch)
Ø 4.877 mm Ø 175.293 mm Ø 175.3751 mm 0.0821 mm G1 =
137-8846 137-8847
(0.1920 inch) (6.9013 inch) (6.90452 inch) (0.00323 inch)
Ø 4.877 mm Ø 154.955 mm Ø 155.0332 mm 0.0782 mm G1 =
162-0268 162-0269
(0.1920 inch) (6.1006 inch) (6.10366 inch) (0.00308 inch)
Ø 6.3500 mm Ø 103.817 mm Ø 103.8876 mm 0.0706 mm
174-7484 174-7483 G1 =
(0.25000 inch) (4.0873 inch) (4.09005 inch) (0.00278 inch)
Ø 6.350 mm Ø 103.815 mm Ø 103.888 mm 0.0706 mm
— 190-5935 G1 =
(0.2500 inch) (4.0872 inch) (4.0901 inch) (0.00278 inch)
Ø 5.001 mm Ø 335.021 mm Ø 335.1356 mm 0.1146 mm G1 =
— 244-1096
(0.1969 inch) (13.1898 inch) (13.19429 inch) (0.00451 inch)
Ø 6.0000 mm Ø 104.953 mm Ø 105.0215 mm 0.0685 mm
317-1300 317-1299 G1 =
(0.23622 inch) (4.13200 inch) (4.13469 inch) (0.00269 inch)
Ø 6.350 mm Ø 103.815 mm Ø 103.888 mm 0.0706 mm
322-8958 175-7528 G1 =
(0.2500 inch) (4.0872 inch) (4.0901 inch) (0.00278 inch)
Ø 3.500 mm Ø 120.910 mm
371-1193 371-1194 G1 =
(0.13780 inch) (4.76023 inch)
Ø 4.877 mm Ø 175.293 mm Ø 175.3751 mm 0.0821 mm
469-1581 469-1582 G1 =
(0.1920 inch) (6.9013 inch) (6.90452 inch) (0.00323 inch)
Ø 6.350 mm Ø 103.815 mm Ø 103.888 mm 0.0706 mm
— 495-4918 G1 =
(0.2500 inch) (4.0872 inch) (4.0901 inch) (0.00278 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Illustration 56 g06369821
Typical example of taking a measurement between pins (B) of a reaction hub spline.
Note: Typical example of a reaction hubwithout bearing journal.
(B) Measurement Between Pins

Table 21
Record Actual Dimensions
Refer to the "Measurement Techniques"
Internal Reaction Hub Spline Dimensions and Tolerances
section for the proper techniques and
number of measurements to be taken.
Original Reusability Maximum
Part
Gage Pin Specification Specification Difference
Number Measurement
(1) Diameter Measurement Measurement High and Low
Between Gage Pins Between Gage Pins Measurement
1V-6273 G1 =

Ø 5.4864 mm Ø 242.0137 mm Ø 242.1111 mm 0.0974 mm

(0.21600 inch) (9.52808 inch) (9.53191 inch) (0.00383 inch)
5D-5452 Ø 4.877 mm Ø 154.955 mm Ø 155.0317 mm 0.07649 mm
G1 =
8D-2091 (0.1920 inch) (6.1006 inch) (6.10360 inch) (0.00301 inch)
Ø 5.4864 mm Ø 465.701 mm Ø 465.8431 mm 0.1421 mm
137-8628 G1 =
(0.21600 inch) (18.3347 inch) (18.34024 inch) (0.00559 inch)
Ø 5.0000 mm Ø 467.1800 mm Ø 467.3218 mm 0.1418 mm
419-6353 G1 =
(0.19685 inch) (18.3929 inch) (18.39846 inch) (0.00558 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Illustration 57 g06321309
Typical example of taking a Measurement Over Pins (MOP) (C) of a reaction hub spline.
(C) Measurement Over Pins (MOP)

Table 22
Record Actual Dimensions
Refer to the "Measurement
External Reaction Hub Spline Dimensions and Tolerances Techniques" section for the proper
techniques and number of
measurements to be taken.
Assembly Original Reusability Maximum
Part
Part Gage Pin Specification Specification Difference
Number Measurement
Number (1) Diameter Measurement Measurement High and Low
(1)
Over Gage Pins Over Gage Pins Measurement
1C-7101 L1 =
Ø 9.7536 mm Ø 448.719 mm Ø 448.5663 mm 0.1527 mm
— 317-4580
(0.3840 inch) (17.6661 inch) (17.66006 inch) (0.00601 inch)
463-9547
Ø 9.525 mm Ø 405.376 mm Ø 405.2098 mm 0.1662 mm L1 =
1V-8610 1V-8608
(0.3750 inch) (15.9597 inch) (15.95311 inch) (0.00654 inch)
Ø 7.9375 mm Ø 359.621 mm Ø 359.4610 mm 0.1600 mm L1 =
2V-5711 2V-5712
(0.3125 inch) (14.1583 inch) (14.15198 inch) (0.00630 inch)
4D-7614 Ø 10.9728 mm Ø 665.594 mm Ø 665.3563 mm 0.2377 mm L1 =
—
6G-6874 (0.4320 inch) (26.2044 inch) (26.19508 inch) (0.00936 inch)
Ø 7.9375 mm Ø 307.848 mm Ø 307.7044 mm 0.1437 mm
4V-0092 175-7527 L1 =
(0.3125 inch) (12.1200 inch) (12.11432 inch) (0.00566 inch)
Ø 9.5250 mm Ø 348.651 mm Ø 348.5246 mm 0.1264 mm
4V-8535 162-9389 L1 =
(0.37500 inch) (13.7264 inch) (13.72141 inch) (0.00498 inch)
Ø 6.3500 mm Ø 273.566 mm Ø 273.4679 mm 0.0981 mm L1 =
4V-9820 4V-9818
(0.25000 inch) (10.7703 inch) (10.76643 inch) (0.00386 inch)
5K-4408 5K-4271 Ø 9.5250 mm Ø 407.3931 mm Ø 407.2342 mm 0.1589 mm L1 =
7K-7462 7K-7463 (0.37500 inch) (16.0391 inch) (16.03281 inch) (0.00626 inch)
5V-4702 L1 =
Ø 14.2875 mm Ø 729.008 mm Ø 728.8048 mm 0.2032 mm
— 5V-8974
(0.56250 inch) (28.7010 inch) (28.69304 inch) (0.00800 inch)
6W-7272
5V-9356 Ø 7.9375 mm Ø 278.488 mm Ø 278.3904 mm 0.0976 mm L1 =
5V-9355
9C-9187 (0.31250 inch) (10.9641 inch) (10.96023 inch) (0.00384 inch)
6K-0461 6K-0462 L1 =
Ø 7.3152 mm Ø 305.7754 mm Ø 305.6725 mm 0.1029 mm
7K-7432 7K-7435
(0.2880 inch) (12.03838 inch) (12.03433 inch) (0.00405 inch)
9C-7457 9C-2975
Ø 6.3500 mm Ø 241.3178 mm Ø 241.2215 mm 0.0963 mm L1 =
6S-7803 6S-3013
(0.25000 inch) (9.5007 inch) (9.49689 inch) (0.00379 inch)
Ø 14.2875 mm Ø 729.008 mm Ø 728.8048 mm 0.2032 mm L1 =
— 6W-7351
(0.56250 inch) (28.7010 inch) (28.69304 inch) (0.00800 inch)
7K-0454 7K-0253 Ø 6.3500 mm Ø 273.5656 mm Ø 273.4870 mm 0.0786 mm
L1 =
7K-7431 7K-7434 (0.25000 inch) (10.77028 inch) (10.76718 inch) (0.00309 inch)
Ø 8.7782 mm Ø 346.9538 mm Ø 346.8259 mm 0.1280 mm
7K-7433 7K-7436 L1 =
(0.34560 inch) (13.65957 inch) (13.65453 inch) (0.00504 inch)
Ø 11.1125 mm Ø 523.145 mm Ø 522.9490 mm 0.1960 mm
8K-0068 9K-0101 L1 =
(0.43750 inch) (20.5962 inch) (20.58850 inch) (0.00772 inch)
— 8P-3133 L1 =

Ø 7.315 mm Ø 351.493 mm Ø 351.3538 mm 0.1392 mm

(0.28799 inch) (13.83828 inch) (13.83280 inch) (0.00548 inch)
Ø 9.5250 mm Ø 405.376 mm Ø 405.2098 mm 0.1662 mm
8V-6382 8V-6387 L1 =
(0.37500 inch) (15.9597 inch) (15.95311 inch) (0.00654 inch)
9C-4811 9C-4812 Ø 9.5250 mm Ø 348.6506 mm Ø 348.5242 mm 0.1264 mm
L1 =
9K-2300 9K-1852 (0.37500 inch) (13.7264 inch) (13.72140 inch) (0.00498 inch)
Ø 7.9375 mm Ø 359.621 mm Ø 359.4610 mm 0.1600 mm
9C-5852 9C-5851 L1 =
(0.3125 inch) (14.1583 inch) (14.15198 inch) (0.00630 inch)
Ø 10.0000 mm Ø 405.883 mm Ø 405.7457 mm 0.1373 mm L1 =
9U-0975 9U-0976
(0.39370 inch) (15.9796 inch) (15.97421 inch) (0.00541 inch)
Ø 20.0000 mm Ø 619.136 mm Ø 618.9847 mm 0.1514 mm L1 =
— 9U-3391
(0.78740 inch) (24.3754 inch) (24.36943 inch) (0.00596 inch)
Ø 5.4864 mm Ø 216.146 mm Ø 215.526 mm 0.620 mm
9W-2977 9W-2976 L1 =
(0.21600 inch) (8.50967 inch) (8.48526 inch) (0.02441 inch)
Ø 16.0000 mm Ø 425.213 mm Ø 425.0991 mm 0.1139 mm L1 =
110-0551 105-8714
(0.62992 inch) (16.74064 inch) (16.73615 inch) (0.00448 inch)
Ø 14.0000 mm Ø 505.564 mm Ø 505.4220 mm 0.1420 mm
110-0552 105-8715 L1 =
(0.55118 inch) (19.9041 inch) (19.89846 inch) (0.00559 inch)
Ø 25.000 mm Ø 892.617 mm Ø 892.4228 mm 0.1942 mm L1 =
— 107-0691
(0.9843 inch) (35.1423 inch) (35.13468 inch) (0.00765 inch)
118-9399 118-9400 Ø 12.0000 mm Ø 524.943 mm Ø 524.8087 mm 0.1343 mm L1 =
162-0193 162-0194 (0.47244 inch) (20.6670 inch) (20.66172 inch) (0.00529 inch)
Ø 12.000 mm Ø 591.324 mm Ø 591.1219 mm 0.2021 mm L1 =
137-8846 137-8847
(0.4724 inch) (23.28043 inch) (23.27247 inch) (0.00796 inch)
Ø 12.0000 mm Ø 524.943 mm Ø 524.8087 mm 0.1343 mm L1 =
162-0268 162-0269
(0.47244 inch) (20.66701 inch) (20.66172 inch) (0.00529 inch)
Ø 7.9375 mm Ø 359.621 mm Ø 359.4610 mm 0.1600 mm
174-7484 174-7483 L1 =
(0.3125 inch) (14.1583 inch) (14.15198 inch) (0.00630 inch)
Ø 7.9375 mm Ø 307.848 mm Ø 307.7044 mm 0.1436 mm
— 190-5935 L1 =
(0.31250 inch) (12.11998 inch) (12.11432 inch) (0.00565 inch)
Ø 25.000 mm Ø 764.435 mm Ø 764.2747 mm 0.1603 mm L1 =
— 244-1096
(0.9843 inch) (30.0958 inch) (30.08949 inch) (0.00631 inch)
Ø 7.9375 mm Ø 359.621 mm Ø 359.4610 mm 0.1600 mm
317-1300 317-1299 L1 =
(0.31250 inch) (14.1583 inch) (14.15198 inch) (0.00630 inch)
Ø 9.5250 mm Ø 348.651 mm Ø 348.5246 mm 0.1264 mm
322-8958 175-7528 L1 =
(0.37500 inch) (13.7264 inch) (13.72141 inch) (0.00498 inch)
Ø 7.9375 mm Ø 359.621 mm Ø 359.4610 mm 0.1600 mm
371-1193 371-1194 L1 =
(0.31250 inch) (14.1583 inch) (14.15198 inch) (0.00630 inch)
Ø 10.0000 mm Ø 408.511 mm Ø 408.369 mm 0.142 mm
469-1581 469-1582 L1 =
(0.39370 inch) (16.0831 inch) (16.0775 inch) (0.0056 inch)
Ø 9.5250 mm Ø 348.651 mm Ø 348.5246 mm 0.1264 mm
— 495-4918 L1 =
(0.37500 inch) (13.7264 inch) (13.72141 inch) (0.00498 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Illustration 58 g06369827
Typical example of taking a Measurement Over Pins (MOP) (C) of a reaction hub spline.
Note: Typical example of a reaction hub without bearing journal.
(C) Measurement Between Pins

Table 23
Record Actual Dimensions
Refer to the "Measurement Techniques"
External Reaction Hub Spline Dimensions and Tolerances
section for the proper techniques and
number of measurements to be taken.
Original Reusability Maximum
Part
Gage Pin Specification Specification Difference
Number Measurement
(1) Diameter Measurement Over Measurement Over High and Low
Gage Pins Gage Pins Measurement
Ø 12.7000 mm Ø 725.2513 mm Ø 725.0331 mm 0.2182 mm
1V-6273 L1 =
(0.50000 inch) (28.5532 inch) (28.54455 inch) (0.00859 inch)
5D-5452 Ø 8.7782 mm Ø 575.1043 mm Ø 575.0208 mm 0.0835 mm
L1 =
8D-2091 (0.3456 inch) (22.6419 inch) (22.63857 inch) (0.00329 inch)
Ø 15.9995 mm Ø 721.563 mm Ø 721.3841 mm 0.1789 mm
137-8628 L1 =
(0.62990 inch) (28.4079 inch) (28.40089 inch) (0.00704 inch)
Ø 20.000 mm
Ø 919.523 mm Ø 919.3459 mm 0.1771 mm
419-6353 (0.7874 inch) L1 =
(36.2016 inch) (36.19465 inch) (0.00697 inch)
(Flattened)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Wheel Bearing Bore and Bearing Journal Reusability

Illustration 59 g06321257
Typical example of outboard bearing (8) placement variations.
Note: The outboard bearing placement is on the spindle of the final drive wheel group on left versus the hub on the right.
(1) Spindle
(3) Hub
(8) Outboard Bearing

The placement of the outboard wheel bearings can be on the hub or spindle. Inspect the spindle and hub bearing journals and the bearing bores of the
wheel for wear at each rebuild.

NOTICE

If the bearing journal or bore has significant wear, the bearings will fit
loosely and will cause premature failure of the components.

Bearing Journal and Bore Inspections

1. Start with a visual inspect of all bearing journal and bores. Bearing bores and journals can be inspected with the naked eye. To provide the best
results, a magnifying glass and a strong light source such as sunlight are recommended. Check each component for cracks, bruising, scratching,
or spalling. It can also be difficult to distinguish between small scratches and small cracks. In these cases, perform Wet Magnetic Particle
Testing (MT) or Liquid Penetrant Testing (PT), refer to the "Crack Detection Methods" section.

2. After passing visual/ Non-Destructive testing, then measure the bearing journal and bores to ensure that the component meets the criteria for
reusability in Table 24 through Table 26.

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

Spindle and Hub Bearing Journal Wear Limits

The outboard bearings are positioned on the spindle in two different ways. The outboard bearings are positioned on the spindle, or the hub which is
then mounted to the spindle. If the bearing is mounted to the hub, the spindle should still be checked for wear in locations where contact locations with
the hub. If the spindle has wear characteristics, thermal spray may be used to salvage the spindle. Refer to the "References" section for applicable
information regarding thermal spray. Refer to Table 24 for part number-specific outer diameter dimensions of spindles.

Spindle Bearing Journal Tolerances

Note: Refer to the "References" section for applicable information regarding thermal spray.

Illustration 60 g06320902
Typical example of a spindle.
(A) Bearing Journal
(B) Spindle Journal

Table 24
Record Actual Dimensions
Refer to the "Measurement Techniques" section for the
Spindle Outside Diameter Tolerance
proper techniques and number of measurements to be
taken.
Part
Tolerance Tolerance
Number Measurement Measurement Measurement
(1) (A) (B)

1V-1317 Ø 165.0822 ± 0.0127 mm Ø 120.6373 ± 0.0127 mm A1 = A2 = A3 =

5K-4267 (6.4993 ± 0.0005 inch) (4.7495 ± 0.0005 inch)
1V-1379 Ø 117.462 ± 0.013 mm Ø 104.762 ± 0.013 mm
A1 = A2 = A3 =
4K-6388 (4.6245 ± 0.0005 inch) (4.1245 ± 0.0005 inch)
1V-1392 A1 = A2 = A3 =
Ø 117.457 ± 0.013 mm Ø 104.762 ± 0.013 mm
2V-5132
(4.6243 ± 0.0005 inch) (4.1245 ± 0.0005 inch)
7K-1138
1V-1554
Ø 95.232 ± 0.013 mm Ø 76.060 ± 0.013 mm
6K-8848 A1 = A2 = A3 =
(3.7493 ± 0.0005 inch) (2.9945 ± 0.0005 inch)
7K-7468
1V-4718 A1 = A2 = A3 =
Ø 95.232 ± 0.013 mm Ø 82.537 ± 0.013 mm
6K-5836
(3.7493 ± 0.0005 inch) (3.2495 ± 0.0005 inch)
7K-7459
1V-4975 Ø 189.962 ± 0.025 mm Ø 155.423 ± 0.025 mm A1 = A2 = A3 =
4V-6103 (7.4788 ± 0.0010 inch) (6.1190 ± 0.001 inch)
Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
2K-5077 A1 = A2 = A3 =
(4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
2K-5176 A1 = A2 = A3 =
(4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
2K-8756 Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
A1 = A2 = A3 =
7K-7526 (4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
2K-9416 Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
A1 = A2 = A3 =
7K-7525 (4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
Ø 199.059 ± 0.076 mm Ø 165.633 ± 0.076 mm
2S-1039 A1 = A2 = A3 =
(7.837 ± 0.0030 inch) (6.521 ± 0.0030 inch)
2V-0050 A1 = A2 = A3 =

Ø 165.66 ± 0.08 mm Ø 121.16 ± 0.08 mm

(6.5220 ± 0.0032 inch) (4.7701 ± 0.0032 inch)
Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
3K-9710 A1 = A2 = A3 =
(4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
3Q-5117
Ø 136.507 ± 0.013 mm Ø 106.365 ± 0.013 mm
3Q-5199 A1 = A2 = A3 =
(5.3743 ± 0.0005 inch) (4.1876 ± 0.0005 inch)
267-7538
Ø 165.085 ± 0.015 mm Ø 123.00 ± 0.013 mm
3Q-6136 A1 = A2 = A3 =
(6.4994 ± 0.0006 inch) (4.8425 ± 0.0005 inch)
Ø 192.062 ± 0.076 mm Ø 165.07 ± 0.03 mm
3S-9042 A1 = A2 = A3 =
(7.5615 ± 0.0030 inch) (6.499 ± 0.001 inch)
Ø 117.94 ± 0.08 mm Ø 95.250 ± 0.508 mm
3V-1241 A1 = A2 = A3 =
(4.6433 ± 0.0032 inch) (3.7500 ± 0.0200 inch)
3V-2478 A1 = A2 = A3 =
Ø 304.770 ± 0.025 mm Ø 260.320 ± 0.025 mm
5V-7635
(11.9988 ± 0.0010 inch) (10.2488 ± 0.0010 inch)
6W-7271
Ø 95.235 ± 0.015 mm A1 = A2 = A3 =
(3.7494 ± 0.0006 inch) Ø 82.537 ± 0.013 mm
3Y-4071
Ø 95.232 ± 0.013 mm (3.2495 ± 0.0005 inch)
(3.7493 ± 0.0005 inch)
Ø 117.460 ± 0.015 mm Ø 104.762 ± 0.013 mm A1 = A2 = A3 =
3Y-5779
(4.62440 ± 0.0006 inch) (4.1245 ± 0.0005 inch)
3Y-7724 A1 = A2 = A3 =
Ø 95.235 ± 0.015 mm Ø 76.060 ± 0.013 mm
4V-9580
(3.7494 ± 0.0006 inch) (2.9945 ± 0.0005 inch)
9C-2312
Ø 304.770 ± 0.025 mm Ø 268.42 ± 0.20 mm
4E-4353 A1 = A2 = A3 =
(11.9988 ± 0.0010 inch) (10.5677 ± 0.0079 inch)
Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
4K-3428 A1 = A2 = A3 =
(4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
4K-3429 A1 = A2 = A3 =
(4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
4V-5213 Ø 136.507 ± 0.013 mm Ø 106.365 ± 0.013 mm A1 = A2 = A3 =
9C-0616 (5.3743 ± 0.0005 inch) (4.1876 ± 0.0005 inch)
4V-9822 A1 = A2 = A3 =
Ø 85.710 ± 0.015 mm Ø 69.77 ± 0.10 mm
4Y-0984
(3.3744 ± 0.0006 inch) (2.7468 ± 0.004 inch)
9C-2313
Ø 117.457 ± 0.013 mm Ø 104.762 ± 0.013 mm A1 = A2 = A3 =
5K-1651
(4.6243 ± 0.0005 inch) (4.1245 ± 0.0005 inch)
Ø 117.932 ± 0.076 mm Ø 99.365 ± 0.127 mm
5K-1681 A1 = A2 = A3 =
(4.643 ± 0.0030 inch) (3.912 ± 0.0050 inch)
Ø 97.28 ± 0.08 mm Ø 79.54 ± 0.14 mm
5K-5496 A1 = A2 = A3 =
(3.8299 ± 0.0032 inch) (3.1315 ± 0.0055 inch)
Ø 97.282 ± 0.076 mm Ø 79.538 ± 0.142 mm
5K-5497 A1 = A2 = A3 =
(3.830 ± 0.0030 inch) (3.1314 ± 0.0056 inch)
5V-4062
Ø 136.576 ± 0.015 mm Ø 106.365 ± 0.013 mm
9C-0615 A1 = A2 = A3 =
(5.3770 ± 0.0006 inch) (4.1876 ± 0.0005 inch)
138-4805
Ø 117.460 ± 0.015 mm Ø 104.762 ± 0.013 mm A1 = A2 = A3 =
5V-5692
(4.62440 ± 0.0006 inch) (4.1245 ± 0.0005 inch)
5Z-6694 Ø 304.770 ± 0.025 mm Ø 300.008 ± 0.025 mm
A1 = A2 = A3 =
6W-7349 (11.9988 ± 0.0010 inch) (11.8113 ± 0.001 inch)
Ø 95.235 ± 0.015 mm Ø 74.35 ± 0.15 mm
6C-2329 A1 = A2 = A3 =
(3.7494 ± 0.0006 inch) (2.9272 ± 0.0059 inch)
Ø 136.510 ± 0.015 mm Ø 106.365 ± 0.013 mm
6C-2331 A1 = A2 = A3 =
(5.3744 ± 0.0006 inch) (4.1876 ± 0.0005 inch)
Ø 136.507 ± 0.013 mm Ø 106.365 ± 0.013 mm
6C-2332 A1 = A2 = A3 =
(5.3743 ± 0.0005 inch) (4.1876 ± 0.0005 inch)
Ø 95.235 ± 0.015 mm Ø 76.060 ± 0.013 mm A1 = A2 = A3 =
6S-3012
(3.7494 ± 0.0006 inch) (2.9945 ± 0.0005 inch)
Ø 192.0621 ± 0.025 mm Ø 165.07 ± 0.03 mm A1 = A2 = A3 =
7K-3737
(7.5615 ± 0.0010 inch) (6.499 ± 0.001 inch)

7K-7467 Ø 97.282 ± 0.076 mm Ø 79.538 ± 0.142 mm A1 = A2 = A3 =

(3.830 ± 0.0030 inch) (3.1314 ± 0.0056 inch)
Ø 97.282 ± 0.076 mm Ø 79.538 ± 0.142 mm
7K-7499 A1 = A2 = A3 =
(3.830 ± 0.0030 inch) (3.1314 ± 0.0056 inch)
Ø 97.282 ± 0.076 mm Ø 79.538 ± 0.142 mm
7K-7525 A1 = A2 = A3 =
(3.830 ± 0.0030 inch) (3.1314 ± 0.0056 inch)
Ø 97.282 ± 0.076 mm Ø 79.538 ± 0.142 mm
7K-7527 A1 = A2 = A3 =
(3.830 ± 0.0030 inch) (3.1314 ± 0.0056 inch)
Ø 192.634 ± 0.076 mm Ø 164.414 ± 0.076 mm
7S-9590 A1 = A2 = A3 =
(7.5840 ± 0.0030 inch) (6.4730 ± 0.0030 inch)
Ø 152.4 - 0.005/ - 0.030 mm Ø 123.0 ± 0.013 mm A1 = A2 = A3 =
7U-0774
(6.00 - 0.0002/ - 0.0012 inch) (4.84 ± 0.0005 inch)
7V-8640 Ø 136.510 ± 0.015 mm Ø 106.365 ± 0.013 mm A1 = A2 = A3 =
9C-2310 (5.3744 ± 0.0006 inch) (4.1876 ± 0.0005 inch)
Ø 236.626 ± 0.127 mm Ø 202.387 ± 0.203 mm
8K-6197 A1 = A2 = A3 =
(9.3160 ± 0.0050 inch) (7.9680 ± 0.0080 inch)
Ø 234.92 ± 0.03 mm Ø 203.17 ± 0.03 mm A1 = A2 = A3 =
8K-6574
(9.249 ± 0.0010 inch) (7.999 ± 0.0010 inch)
Ø 189.941 ± 0.025 mm Ø 169.944 ± 0.025 mm A1 = A2 = A3 =
8K-6929
(7.4780 ± 0.0010 inch) (6.6907 ± 0.0010 inch)
8R-6509 Ø 488.92 ± 0.025 mm Ø 479.395 ± 0.025 mm
A1 = A2 = A3 =
137-8627 (19.2488 ± 0.0010 inch) (18.8738 ± 0.0010 inch)
Ø 234.9246 ± 0.025 mm Ø 203.175 ± 0.03 mm A1 = A2 = A3 =
8S-4173
(9.249 ± 0.0010 inch) (7.999 ± 0.001 inch)
Ø 165.085 ± 0.015 mm Ø 123.000 ± 0.013 mm A1 = A2 = A3 =
8V-6388
(6.4994 ± 0.0006 inch) (4.8425 ± 0.0005 inch)
Ø 139.750 ± 0.015 mm Ø 106.365 ± 0.013 mm
8X-0491 A1 = A2 = A3 =
(5.5020 ± 0.0006 inch) (4.1876 ± 0.0005 inch)
9C-1639 A1 = A2 = A3 =
Ø 120.025 ± 0.015 mm Ø 104.762 ± 0.013 mm
9C-2244
(4.7254 ± 0.0006 inch) (4.1245 ± 0.0005 inch)
138-4804
Ø 117.94 ± 0.08 mm Ø 99.36 ± 0.15 mm
9C-2976 A1 = A2 = A3 =
(4.6433 ± 0.0032 inch) (3.9118 ± 0.0059 inch)
9K-1175 Ø 123.8123 ± 0.0127 mm Ø 104.7623 ± 0.013 mm A1 = A2 = A3 =
9K-4966 (4.8745 ± 0.0005 inch) (4.1245 ± 0.0005 inch)
9Q-5379 Ø 190.075 ± 0.025 mm Ø 155.423 ± 0.025 mm A1 = A2 = A3 =
388-4764 (7.4833 ± 0.0010 inch) (6.1190 ± 0.0010 inch)
9U-3387 Ø 330.3 ± 0.025 mm Ø 285.50 ± 0.025 mm
A1 = A2 = A3 =
116-6260 (13.00 ± 0.0010 inch) (11.2401 ± 0.0010 inch)
Ø 189.965 ± 0.025 mm Ø 169.965 ± 0.025 mm
9V-1330 A1 = A2 = A3 =
(7.4789 ± 0.0010 inch) (6.6915 ± 0.0010 inch)
Ø 136.507 ± 0.013 mm Ø 106.365 ± 0.013 mm
9V-7141 A1 = A2 = A3 =
(5.3743 ± 0.0005 inch) (4.1876 ± 0.0005 inch)
105-8725
Ø 174.7 ± 0.025 mm Ø 155.423 ± 0.025 mm
135-7742 A1 = A2 = A3 =
(6.88 ± 0.0010 inch) (6.1190 ± 0.0010 inch)
417-0990
Ø 89.961 ± 0.008 mm Ø 64.57 ± 0.11 mm
106-1597 A1 = A2 = A3 =
(3.5418 ± 0.0003 inch) (2.5421 ± 0.0043 inch)
114-2548
Ø 189.962 ± 0.025 mm Ø 155.423 ± 0.025 mm
142-7562 A1 = A2 = A3 =
(7.4788 ± 0.0010 inch) (6.1190 ± 0.0010 inch)
197-8287
Ø 136.507 ± 0.013 mm Ø 106.365 ± 0.013 mm
122-6631 A1 = A2 = A3 =
(5.3743 ± 0.0005 inch) (4.1876 ± 0.0005 inch)
Ø 330.3 ± 0.025 mm Ø 285.50 ± 0.025 mm A1 = A2 = A3 =
131-1296
(13.00 ± 0.0010 inch) (11.2401 ± 0.0010 inch)
Ø 139.750 ± 0.015 mm Ø 106.365 ± 0.013 mm
139-1472 A1 = A2 = A3 =
(5.5020 ± 0.0006 inch) (4.1876 ± 0.0005 inch)
Ø 120.025 ± 0.015 mm Ø 104.762 ± 0.013 mm
140-6412 A1 = A2 = A3 =
(4.7254 ± 0.0006 inch) (4.1245 ± 0.0005 inch)
147-6457 A1 = A2 = A3 =

Ø 209.65 ± 0.025 mm Ø 175.736 ± 0.025 mm

(8.2539 ± 0.0010 inch) (6.9187 ± 0.0010 inch)
151-3036 Ø 209.65 ± 0.025 mm Ø 175.736 ± 0.025 mm A1 = A2 = A3 =
489-3400 (8.2539 ± 0.0010 inch) (6.9187 ± 0.0010 inch)
180-0017 Ø 171.525 ± 0.025 mm Ø 155.423 ± 0.025 mm A1 = A2 = A3 =
392-7976 (6.7529 ± 0.0010 inch) (6.1190 ± 0.0010 inch)
205-0747 Ø 174.7 ± 0.025 mm Ø 155.423 ± 0.025 mm A1 = A2 = A3 =
482-1805 (6.88 ± 0.0010 inch) (6.1190 ± 0.0010 inch)
Ø 139.750 ± 0.015 mm Ø 106.365 ± 0.013 mm
218-8117 A1 = A2 = A3 =
(5.5020 ± 0.0006 inch) (4.1876 ± 0.0005 inch)
Ø 355.7 ± 0.025 mm Ø 335.912 ± 0.025 mm A1 = A2 = A3 =
244-1095
(14.00 ± 0.0010 inch) (13.2249 ± 0.0010 inch)
Ø 174.7 ± 0.025 mm Ø 155.423 ± 0.025 mm A1 = A2 = A3 =
353-8391
(6.88 ± 0.0010 inch) (6.1190 ± 0.001 inch)
Ø 139.750 ± 0.015 mm Ø 121.365 ± 0.013 mm
365-4324 A1 = A2 = A3 =
(5.5020 ± 0.0006 inch) (4.7781 ± 0.0005 inch)
Ø 174.7 ± 0.025 mm Ø 155.423 ± 0.025 mm
382-0663 A1 = A2 = A3 =
(6.88 ± 0.0010 inch) (6.1190 ± 0.001 inch)
Ø 174.7 ± 0.025 mm Ø 155.423 ± 0.025 mm
417-0990 A1 = A2 = A3 =
(6.88 ± 0.0010 inch) (6.1190 ± 0.0010 inch)
Ø 488.92 ± 0.025 mm Ø 468.5 ± 0.025 mm
419-6350 A1 = A2 = A3 =
(19.249 ± 0.0010 inch) (18.44 ± 0.0010 inch)
Ø 174.7 ± 0.025 mm Ø 155.423 ± 0.025 mm A1 = A2 = A3 =
434-3964
(6.88 ± 0.0010 inch) (6.1190 ± 0.0010 inch)
Ø 190.1 ± 0.025 mm Ø 175.736 ± 0.025 mm
469-1579 A1 = A2 = A3 =
(7.4842 ± 0.0010 inch) (6.9187 ± 0.0010 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Reaction Hub Bearing Journal Tolerances

Note: Refer to the "References" section for applicable information regarding thermal spray.

Illustration 61 g06320923
Typical example of a reaction hub.
(C) Bearing Journal

The reaction hub shown in Illustration 61 is designed with a bearing journal (C). When inspecting this design, the hub and the spindle should be
inspected and measured. The hub must meet specifications for new parts and the hub must have no abrasive wear or adhesive wear. If the reaction hub
does not meet the required conditions, the hub can be reworked by use of thermal spray and machining. Refer to Table 25 for tolerances of reaction
hub bearing journal.

Table 25
Record Actual Dimensions
Reaction Hub Bearing Journal Tolerances Refer to the "Measurement Techniques" section for the proper techniques
and number of measurements to be taken.
Assembly Part
Tolerance
Part Number Measurement Measurement Measurement
(C)
Number (1) (1)

1C-7312 1C-7101 C1 = C2 = C3 =
Ø 203.3 ± 0.025 mm
317-4581 317-4580
(8.00 ± 0.0010 inch)
463-9549 463-9547
Ø 165.085 ± 0.015 mm C1 = C2 = C3 =
1V-8610 1V-8608
(6.4994 ± 0.0006 inch)
Ø 146.035 ± 0.015 mm C1 = C2 = C3 =
2V-5711 2V-5712
(5.7494 ± 0.0006 inch)
4D-7614 Ø 254.00 ± 3.048 mm C1 = C2 = C3 =
—
6G-6874 (10.00 ± 0.12 inch)
138-4802
Ø 146.1 ± 0.015 mm
4V-0092 138-4803 C1 = C2 = C3 =
(5.75 ± 0.0006 inch)
175-7527

4V-8535 162-9389 Ø 146.1 ± 0.015 mm C1 = C2 = C3 =

(5.75 ± 0.0006 inch)
Ø 96.823 ± 0.015 mm C1 = C2 = C3 =
4V-9820 4V-9818
(3.8119 ± 0.0006 inch)
5K-4271 Ø 165.082 ± 0.013 mm
5K-4408 7K-7462 C1 = C2 = C3 =
7K-7463 (6.4993 ± 0.0005 inch)
5V-4702 C1 = C2 = C3 =
Ø 295.00 ± 0.025 mm
— 5V-8974
(11.6142 ± 0.001 inch)
6W-7272
5V-9356 Ø 107.937 ± 0.013 mm C1 = C2 = C3 =
5V-9355
9C-9187 (4.2495 ± 0.0005 inch)
6K-0461 6K-0462 C1 = C2 = C3 =
Ø 117.462 ± 0.013 mm
7K-7432 7K-7435
(4.6245 ± 0.0005 inch)
9C-7457 9C-2975
Ø 107.937 ± 0.013 mm C1 = C2 = C3 =
6S-7803 6S-3013
(4.2495 ± 0.0005 inch)
7K-0454 7K-0253 Ø 107.937 ± 0.013 mm C1 = C2 = C3 =
7K-7431 7K-7434 (4.2495 ± 0.0005 inch)
Ø 146.037 ± 0.013 mm
7K-7433 7K-7436 C1 = C2 = C3 =
(5.7495 ± 0.0005 inch)
Ø 165.082 ± 0.013 mm C1 = C2 = C3 =
7K-7462 7K-7463
(6.4993 ± 0.0005 inch)
Ø 206.375 ± 0.025 mm
8K-0068 9K-0101 C1 = C2 = C3 =
(8.125 ± 0.0010 inch)
Ø 165.085 ± 0.015 mm C1 = C2 = C3 =
8V-6382 8V-6387
(6.4994 ± 0.0006 inch)
9C-4811 9C-4812 Ø 146.037 ± 0.013 mm
C1 = C2 = C3 =
9K-2300 9K-1852 (5.7495 ± 0.0005 inch)
Ø 146.035 ± 0.015 mm
9C-5852 9C-5851 C1 = C2 = C3 =
(5.7494 ± 0.0006 inch)
Ø 165.085 ± 0.015 mm
9U-0975 9U-0976 C1 = C2 = C3 =
(6.4994 ± 0.0006 inch)
Ø 355.57 ± 0.25 mm
— 9U-3391 C1 = C2 = C3 =
(13.9988 ± 0.01 inch)
Ø 114.275 ± 0.01 mm
9W-2977 9W-2976 C1 = C2 = C3 =
(4.4990 ± 0.0004 inch)
Ø 206.375 ± 0.015 mm C1 = C2 = C3 =
110-0551 105-8714
(8.125 ± 0.0006 inch)
Ø 206.375 ± 0.015 mm C1 = C2 = C3 =
110-0552 105-8715
(8.125 ± 0.0006 inch)
Ø 385.862 ± 0.025 mm C1 = C2 = C3 =
— 107-0691
(15.1914 ± 0.001 inch)
118-9399 118-9400 Ø 206.375 ± 0.025 mm C1 = C2 = C3 =
162-0193 162-0194 (8.125 ± 0.0010 inch)
Ø 237.43 ± 0.025 mm C1 = C2 = C3 =
137-8846 137-8847
(9.3476 ± 0.001 inch)
Ø 206.375 ± 0.025 mm C1 = C2 = C3 =
162-0268 162-0269
(8.125 ± 0.0010 inch)
Ø 146.035 ± 0.015 mm
174-7484 174-7483 C1 = C2 = C3 =
(5.7494 ± 0.0006 inch)
Ø 146.100 ± 0.015 mm
— 190-5935 C1 = C2 = C3 =
(5.7520 ± 0.0006 inch)
Ø 457.3 ± 0.025 mm C1 = C2 = C3 =
— 244-1096
(18.00 ± 0.0010 inch)
Ø 170.05 ± 0.015 mm
317-1300 317-1299 C1 = C2 = C3 =
(6.695 ± 0.0006 inch)
Ø 146.100 ± 0.015 mm
322-8958 175-7528 C1 = C2 = C3 =
(5.7520 ± 0.0006 inch)
Ø 170.05 ± 0.015 mm
371-1193 371-1194 C1 = C2 = C3 =
(6.6949 ± 0.0006 inch)

— 469-1582 Ø 235.05 ± 0.025 mm C1 = C2 = C3 =

(9.2539 ± 0.0010 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Wheel Bearing Bore Tolerances

Determine the maximum allowable wear of the bore of the bearing cup of the wheel assembly with the following procedure:

1. Measure the Inside Diameter (ID) of the bearing bores of the wheel. Refer to the "Measurement Techniques" section.

2. Refer to Table 26 to verify that the measurement is within the specifications.

3. If there is significant wear or the bore is not within the specifications, the wheel must be replaced or salvaged. To salvage the bore of the wheel,
refer to the "References" section for applicable thermal spray options.

Illustration 62 g06321589
Typical example of a wheel.
(D) Inboard Bearing Bore
(E) Outboard Bearing Bore

Table 26
Record Actual Dimensions
Refer to the "Measurement Techniques"
Wheel Bearing Bore Tolerances
section for the proper techniques and number
of measurements to be taken.
Assembly
Part Inboard Outboard
Part
Number Tolerance Tolerance Measurement Measurement Measurement
Number (1)
(1) (D) (E)

Ø 225.357 + 0.040 - 0.080 mm Ø 225.357 + 0.040 - 0.080 mm

117-0317 2V-0051 A1 = A2 = A3 =
(8.8723 + 0.0016 - 0.0032 inch) (8.8723 + 0.0016 - 0.0032 inch)
Ø 634.795 ± 0.045 mm Ø 679.372 ± 0.045 mm
179-2239 8R-6578 A1 = A2 = A3 =
(24.9919 ± 0.0018 inch) (26.7469 ± 0.0018 inch)
1V-0190
1V-0189 Ø 180.9115 ± 0.0356 mm Ø 193.6115 ± 0.0355 mm
1V-0633 A1 = A2 = A3 =
1V-0634 (7.1225 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
3V-4143
1V-1686
Ø 180.9115 ± 0.0356 mm Ø 193.6115 ± 0.0355 mm
1V-5815 1V-1687 A1 = A2 = A3 =
(7.1225 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
3V-4058
1V-1996 Ø 152.3365 ± 0.0356 mm Ø 158.687 ± 0.035 mm A1 = A2 = A3 =
1V-1997
1V-3254 (5.9975 ± 0.0014 inch) (6.2475 ± 0.0014 inch)
Ø 152.3365 ± 0.036 mm Ø 180.912 ± 0.036 mm
1V-3520 1V-3521 A1 = A2 = A3 =
(5.9975 ± 0.0014 inch) (7.1225 ± 0.0014 inch)
102-2059
Ø 259.892 + 0.040 - 0.080 mm Ø 282.507 + 0.040 - 0.080 mm
1V-5804 1V-4976 A1 = A2 = A3 =
(10.2320 + 0.0016 - 0.0032 inch) (11.1223 + 0.0016 - 0.0032 inch)
9V-1290
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm A1 = A2 = A3 =
1V-6518 1V-6519
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
Ø 253.93 ± 0.04 mm Ø 225.357 ± 0.040 mm A1 = A2 = A3 =
— 2U-6613
(9.9972 ± 0.0016 inch) (8.8723 ± 0.0016 inch)
Ø 266.6492 ± 0.0381 mm Ø 247.5992 ± 0.0381 mm A1 = A2 = A3 =
3S-9040 3S-9044
(10.4980 ± 0.0015 inch) (9.7480 ± 0.0015 inch)
4V-1403
Ø 406.332 + 0.040 - 0.080 mm Ø 422.202 + 0.045 - 0.090 mm
3V-2672 9V-1394 A1 = A2 = A3 =
(15.9973 + 0.0016 - 0.0032 inch) (16.62209 + 0.0018 - 0.0035 inch)
9V-9860
Ø 225.357 + 0.040 - 0.080 mm Ø 225.357 + 0.040 - 0.080 mm
3V-3626 2V-0051 A1 = A2 = A3 =
(8.8723 + 0.0016 - 0.0032 inch) (8.8723 + 0.0016 - 0.0032 inch)
Ø 225.356 ± 0.040 mm Ø 225.357 ± 0.040 mm
— 3V-5513 A1 = A2 = A3 =
(8.8723 ± 0.0016 inch) (8.8723 ± 0.0016 inch)
3V-4266
8K-6951 Ø 180.912 ± 0.035 mm Ø 193.612 ± 0.035 mm
4K-6765 A1 = A2 = A3 =
7K-8818 (7.1225 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
8K-6953
3Y-4632 3Y-0509 A1 = A2 = A3 =

Ø 180.924 ± 0.025 mm Ø 193.624 ± 0.025 mm

(7.123 ± 0.001 inch) (7.623 ± 0.001 inch)
Ø 152.337 ± 0.035 mm Ø 158.674 ± 0.025 mm A1 = A2 = A3 =
3Y-8283 3Y-8281
(5.9975 ± 0.0014 inch) (6.2470 ± 0.001 inch)
Ø 266.6492 ± 0.0381 mm Ø 247.5992 ± 0.0381 mm A1 = A2 = A3 =
— 4S-6855
(10.4980 ± 0.0015 inch) (9.7480 ± 0.0015 inch)
Ø 152.3365 ± 0.0356 mm Ø 180.9242 ± 0.0254 mm A1 = A2 = A3 =
— 4V-4574
(5.9975 ± 0.0014 inch) (7.123 ± 0.001 inch)
Ø 152.3365 ± 0.0356 mm Ø 158.687 ± 0.035 mm
— 4V-4591 A1 = A2 = A3 =
(5.9975 ± 0.0014 inch) (6.2475 ± 0.0014 inch)
Ø 180.912 ± 0.035 mm Ø 193.612 ± 0.035 mm A1 = A2 = A3 =
— 4V-7602
(7.1225 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 190.437 ± 0.035 mm Ø 193.612 ± 0.035 mm
4V-8532 5V-4061 A1 = A2 = A3 =
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 136.465 ± 0.035 mm Ø 148.370 ± 0.035 mm A1 = A2 = A3 =
— 4V-9819
(5.3726 ± 0.0014 inch) (5.8413 ± 0.0014 inch)
Ø 152.349 ± 0.025 mm Ø 158.674 ± 0.025 mm A1 = A2 = A3 =
5C-1498 5C-1491
(5.998 ± 0.001 inch) (6.2470 ± 0.001 inch)
Ø 180.924 ± 0.025 mm Ø 193.624 ± 0.025 mm
— 5C-6319 A1 = A2 = A3 =
(7.1230 ± 0.0010 inch) (7.6230 ± 0.0010 inch)
Ø 180.9115 ± 0.0356 mm Ø 193.6115 ± 0.0355 mm A1 = A2 = A3 =
5K-1217 5K-1076
(7.1225 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
5K-4703
5K-4497 Ø 225.356 ± 0.041 mm Ø 225.356 ± 0.041 mm
6K-8935 A1 = A2 = A3 =
7K-9288 (8.8723 ± 0.0016 inch) (8.8723 ± 0.0016 inch)
7K-3423
Ø 149.912 ± 0.035 mm Ø 158.687 ± 0.035 mm A1 = A2 = A3 =
— 5V-9357
(5.9020 ± 0.0014 inch) (6.2475 ± 0.0014 inch)
6K-5832 6K-5840 Ø 152.35 ± 0.03 mm Ø 180.92 ± 0.03 mm
A1 = A2 = A3 =
8K-8269 8K-8242 (5.998 ± 0.001 inch) (7.123 ± 0.001 inch)
Ø 149.94 ± 0.03 mm Ø 158.70 ± 0.03 mm A1 = A2 = A3 =
6S-3020 6S-3010
(5.903 ± 0.001 inch) (6.248 ± 0.001 inch)
Ø 259.892 + 0.040 - 0.080 mm Ø 239.907 + 0.035 - 0.070 mm A1 = A2 = A3 =
— 7V-0592
(10.2320 + 0.0016 - 0.0032 inch) (9.4451 + 0.0014 - 0.0028 inch)
Ø 314.2742 ± 0.0381 mm Ø 282.5242 ± 0.0381 mm
8K-6556 8K-6559 A1 = A2 = A3 =
(12.3730 ± 0.0015 inch) (11.1230 ± 0.0015 inch)
Ø 193.62 ± 0.03 mm Ø 180.98 ± 0.03 mm A1 = A2 = A3 =
8K-6846 8K-6295
(7.623 ± 0.001 inch) (7.125 ± 0.001 inch)
Ø 266.6492 ± 0.0381 mm Ø 247.5992 ± 0.0381 mm A1 = A2 = A3 =
8K-8143 8K-8116
(10.4980 ± 0.0015 inch) (9.7480 ± 0.0015 inch)
Ø 266.6492 ± 0.0381 mm Ø 247.5992 ± 0.0381 mm A1 = A2 = A3 =
— 8K-8796
(10.4980 ± 0.0015 inch) (9.7480 ± 0.0015 inch)
Ø 190.437 ± 0.035 mm Ø 193.612 ± 0.035 mm
— 8R-4087 A1 = A2 = A3 =
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
8V-6391 Ø 190.436 ± 0.035 mm Ø 193.611 ± 0.035 mm A1 = A2 = A3 =
8V-6392
103-5961 (7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 190.436 ± 0.035 mm Ø 203.150 ± 0.035 mm
— 8X-6842 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.9980 ± 0.0014 inch)
Ø 190.436 ± 0.035 mm Ø 203.150 ± 0.035 mm
— 8X-6843 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.9980 ± 0.0014 inch)
9C-1638 Ø 179.936 ± 0.035 mm Ø 193.612 ± 0.035 mm A1 = A2 = A3 =
—
9C-4597 (7.0841 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 136.465 ± 0.035 mm Ø 148.370 ± 0.035 mm A1 = A2 = A3 =
— 9C-3920
(5.3726 ± 0.0014 inch) (5.8413 ± 0.0014 inch)
Ø 179.936 ± 0.035 mm Ø 193.612 ± 0.035 mm
— 9C-4597 A1 = A1 = A1 =
(7.0841 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 182.4990 ± 0.0356 mm Ø 193.6115 ± 0.0355 mm A1 = A2 = A3 =
9K-1174 9K-1173
(7.1850 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm
9K-4103 9K-4104 A1 = A2 = A3 =
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)

9K-4254 8K-6930 Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm A1 = A2 = A3 =

(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm A1 = A2 = A3 =
— 9K-4822
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
Ø 259.9131 ± 0.0381 mm Ø 239.9182 ± 0.038 mm A1 = A2 = A3 =
— 9K-4829
(10.2328 ± 0.0015 inch) (9.4456 ± 0.0015 inch)
Ø 257.1242 ± 0.0381 mm Ø 247.5992 ± 0.0381 mm A1 = A2 = A3 =
9M-3950 9M-3949
(10.1230 ± 0.0015 inch) (9.7480 ± 0.0015 inch)
Ø 314.27 ± 0.038 mm Ø 282.525 + 0.04 - 0.08 mm A1 = A2 = A3 =
9M-8588 9M-8589
(12.37 ± 0.0015 inch) (11.12301 + 0.0016 - 0.0032 inch)
Ø 415.851 + 0.045 - 0.090 mm Ø 444.43 ± 0.045 mm
— 9U-3388 A1 = A2 = A3 =
(16.3721+ 0.0018 - 0.0035 inch) (17.50 ± 0.0018 inch)
Ø 259.892 + 0.040 - 0.080 mm Ø 239.907 + 0.035 - 0.070 mm
— 9U-4725 A1 = A2 = A3 =
(10.2320 + 0.0016 - 0.0032 inch) (9.4451 + 0.0014 - 0.0028 inch)
Ø 190.437 ± 0.035 mm Ø 193.6115 ± 0.0355 mm A1 = A2 = A3 =
— 9V-9008
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 190.436 ± 0.035 mm Ø 193.6115 ± 0.0355 mm A1 = A2 = A3 =
— 101-8389
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 415.851 + 0.045 - 0.090 mm Ø 514.276 + 0.045 - 0.090 mm A1 = A2 = A3 =
— 107-0692
(16.3721+ 0.0018 - 0.0035 inch) (20.24705 + 0.0018 - 0.0035 inch)
Ø 190.436 ± 0.035 mm Ø 203.150 ± 0.035 mm
— 107-5572 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.9980 ± 0.0014 inch)
Ø 190.436 ± 0.035 mm Ø 203.150 ± 0.035 mm
— 107-5577 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.9980 ± 0.0014 inch)
Ø 259.892 + 0.04 - 0.08 mm Ø 282.525 + 0.04 - 0.08 mm A1 = A2 = A3 =
— 115-9755
(10.23195 + 0.0016 - 0.0032 inch) (11.12301 + 0.0016 - 0.0032 inch)
Ø 247.600 + 0.04 - 0.08 mm Ø 282.525 + 0.04 - 0.08 mm A1 = A2 = A3 =
— 129-3045
(9.74801 + 0.0016 - 0.0032 inch) (11.12301 + 0.0016 - 0.0032 inch)
Ø 317.45 + 0.04 - 0.08 mm Ø 336.5 + 0.04 - 0.08 mm
— 137-8845 A1 = A2 = A3 =
(12.498 + 0.002 - 0.003 inch) (13.25 + 0.002 - 0.003 inch)
Ø 179.920 ± 0.035 mm Ø 193.612 ± 0.035 mm
— 138-2316 A1 = A1 = A1 =
(7.0835 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 190.437 ± 0.035 mm Ø 193.612 ± 0.035 mm
— 138-2317 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 190.436 ± 0.035 mm Ø 203.150 ± 0.035 mm
— 139-6978 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.9980 ± 0.0014 inch)
Ø 317.45 + 0.04 - 0.08 mm Ø 336.5 + 0.04 - 0.08 mm A1 = A2 = A3 =
— 151-3038
(12.498 + 0.002 - 0.003 inch) (13.25 + 0.002 - 0.003 inch)
Ø 190.436 ± 0.035 mm Ø 193.6115 ± 0.0355 mm A1 = A2 = A3 =
— 154-1383
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 190.437 ± 0.035 mm Ø 203.135 ± 0.035 mm A1 = A2 = A3 =
— 155-4858
(7.4975 ± 0.0014 inch) (7.9974 ± 0.0014 inch)
Ø 215.850 ± 0.035 mm Ø 222.200 ± 0.035 mm
— 161-9772 A1 = A1 = A1 =
(8.4980 ± 0.0014 inch) (8.7480 ± 0.0014 inch)
Ø 215.850 ± 0.035 mm Ø 222.200 ± 0.035 mm
— 161-9773 A1 = A1 = A1 =
(8.4980 ± 0.0014 inch) (8.7480 ± 0.0014 inch)
Ø 215.850 ± 0.035 mm Ø 222.200 ± 0.035 mm
— 161-9774 A1 = A1 = A1 =
(8.4980 ± 0.0014 inch) (8.7480 ± 0.0014 inch)
Ø 215.850 ± 0.035 mm Ø 222.200 ± 0.035 mm
— 161-9775 A1 = A1 = A1 =
(8.4980 ± 0.0014 inch) (8.7480 ± 0.0014 inch)
Ø 260.28 ± 0.04 mm Ø 282.525 + 0.04 - 0.08 mm A1 = A2 = A3 =
— 180-0016
(10.247 ± 0.002 inch) (11.123 + 0.002 - 0.003 inch)
Ø 259.89 ± 0.04 mm Ø 292.05 + 0.00 - 0.04 mm A1 = A2 = A3 =
— 186-8808
(10.232 ± 0.002 inch) (11.498 + 0.00 - 0.002 inch)
Ø 190.437 ± 0.035 mm Ø 193.612 ± 0.035 mm
— 200-2902 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 247.600 + 0.04 - 0.08 mm Ø 282.525 + 0.04 - 0.08 mm A1 = A2 = A3 =
— 205-0930
(9.748 + 0.002 - 0.003 inch) (11.123 + 0.002 - 0.003 inch)
— 217-6291 A1 = A1 = A1 =

Ø 215.850 ± 0.035 mm Ø 222.200 ± 0.035 mm

(8.4980 ± 0.0014 inch) (8.7480 ± 0.0014 inch)
Ø 215.850 ± 0.035 mm Ø 222.200 ± 0.035 mm
— 232-1120 A1 = A1 = A1 =
(8.4980 ± 0.0014 inch) (8.7480 ± 0.0014 inch)
Ø 501.576 + 0.045 - 0.090 mm Ø 603.176 + 0.045 - 0.090 mm A1 = A2 = A3 =
— 244-1097
(19.7471 + 0.0018 - 0.0035 inch) (23.7470 + 0.0018 - 0.0035 inch)
Ø 317.45 + 0.04 - 0.08 mm Ø 336.5 + 0.04 - 0.08 mm
— 250-9983 A1 = A2 = A3 =
(12.498 + 0.002 - 0.003 inch) (13.25 + 0.002 - 0.003 inch)
Ø 247.600 + 0.04 - 0.08 mm Ø 282.525 + 0.04 - 0.08 mm
— 319-5239 A1 = A2 = A3 =
(9.74801 + 0.0016 - 0.0032 inch) (11.12301 + 0.0016 - 0.0032 inch)
Ø 247.60 + 0.04 - 0.08 mm Ø 282.525 + 0.04 - 0.08 mm
— 319-5240 A1 = A2 = A3 =
(9.748 + 0.002 - 0.003 inch) (11.1230 + 0.002 - 0.003 inch)
Ø 190.437 ± 0.035 mm Ø 193.612 ± 0.035 mm
— 322-7317 A1 = A1 = A1 =
(7.4975 ± 0.0014 inch) (7.6225 ± 0.0014 inch)
Ø 215.850 ± 0.035 mm Ø 239.925 ± 0.035 mm
— 365-4323 A1 = A1 = A1 =
(8.4980 ± 0.0014 inch) (9.4459 ± 0.0014 inch)
Ø 215.850 ± 0.035 mm Ø 239.95 ± 0.035 mm
— 367-0059 A1 = A1 = A1 =
(8.4980 ± 0.0014 inch) (9.4468 ± 0.0014 inch)
Ø 247.600 + 0.04 - 0.08 mm Ø 282.525 + 0.04 - 0.08 mm A1 = A2 = A3 =
— 367-0818
(9.7480 + 0.002 - 0.003 inch) (11.1230 + 0.002 - 0.003 inch)
Ø 215.850 ± 0.035 mm Ø 239.95 ± 0.035 mm
— 376-0969 A1 = A2 = A3 =
(8.4980 ± 0.0014 inch) (9.4468 ± 0.0014 inch)
Ø 193.612 ± 0.035 mm Ø 190.437 ± 0.035 mm
— 385-1780 A1 = A1 = A1 =
(7.6225 ± 0.0014 inch) (7.4975 ± 0.0014 inch)
Ø 634.795 ± 0.045 mm Ø 679.372 ± 0.045 mm
419-6352 419-6351 A1 = A2 = A3 =
(24.9919 ± 0.0018 inch) (26.7469 ± 0.0018 inch)
Ø 259.95+ 0.04 - 0.08 mm Ø 314.275 + 0.04 - 0.08 mm
— 469-1580 A1 = A2 = A3 =
(10.2342 + 0.002 - 0.003 inch) (12.3729 + 0.002 - 0.003 inch)
Ø 239.950 ± 0.0350 mm Ø 215.85 ± 0.035 mm
— 495-8244 A1 = A1 = A1 =
(9.4500 ± 0.0014 inch) (8.49801 ± 0.00138 inch)
Ø 215.85 ± 0.035 mm Ø 239.925 ± 0.035 mm
— 529-7688 A1 = A1 = A1 =
(8.500 ± 0.002 inch) (9.4459 ± 0.0014 inch)
Ø 259.89 ± 0.04 mm Ø 272.0 ± 0.5 mm
560-7980 561-5851 A1 = A1 = A1 =
(10.2319 ± 0.0016 inch) (10.7086 ± 0.0197 inch)
(1)
Note: The most current part number is identified in bold font when multiple part numbers are in a cell.

Bearing Bore Thermal Spray Procedures

Part Description

Table 27
Base Metal Ductile Iron
Hardness —

Arc Spray Equipment and Procedure

Table 28
Arc Spray Equipment
Maximum Surface Texture 3.5 µm (137.8 µinch)
Reason for Spraying Wear, bearing failure
Mating Part Contact Area & Material Bearing race
SmartArc by Oerlikon Metco PPG Electric Arc Gun, TAFA 8830 MHU, or TAFA 8835
Arc Spray Equipment Type
MHU
Wire TAFA Top 30T Wire Coat, TAFA 75B Bond Coat
Finish Thickness As Required
Spray Angle 90°
Substrate Pre-Heat Temperature 66° C (150° F) Do not direct arc on area to be sprayed
148° C (300° F)

Substrate Temperature During Spraying Not to

Exceed
Auxiliary Cooling Filtered shop air
Rotation/Traverse Device Lathe or headstock/tailstock arrangement, rotary turntable
Rotation Speed 92 SMPM (300.00 SFPM)
Surface Preparation Method Undercut and Grit blast
Equipment Required Lathe/Mill
Recommended Cutting Tool ISCAR DNMG 432 TFIC507
Blast Media Recommendation Pressure Type Only (Aluminum Oxide Grit)

Table 29
Arc Spray Procedure
Arc Spray Procedure Check List
Clean Part Degrease in hot caustic solution
Undercut To "tru-up" surface
Chamfer If required - 1.0 mm (0.039 inch) x 45°
Remove Oxide Use fiber flap brush, Clean/strip disc, emery cloth, or glass bead blaster
Clean Spray Area Commercial degreaser
Mask for Grit Blaster Duct tape
Grit Blast Equipment Pressure type only
Grit Type and Size 20 mesh aluminum oxide
Blast Air Pressure 690 kPa (100.0 psi)
Blast Nozzle to Work Distance 51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask Remove mask material, make sure that surface is clean
Mask for Metal Spray Antibond or Blue Layout Dye
Metal Spray Equipment Type SmartArc by Oerlikon Metco TAFA
Consumable (Bondcoat TAFA 75B TAFA 75B
Clamp Pressure 275 kPa (40 psi)
Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 30V 30V
Amps 125 Amps 150 Amps
Gun to Work Distance (Standoff) 128 mm (5.0 inch) 128 mm (5.0 inch)
Spray Rate/Bond Pass 0.038 mm (0.0015 inch)/pass 0.038 mm (0.0015 inch)/pass
Consumable (Topcoat) TAFA 30T TAFA 30T
Clamp Pressure 275 kPa (40 psi)
Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 31V 31V
Amps 150 Amps 175 Amps
Gun to Work Distance (Standoff) 166 mm (6.5 inch) 166 mm (6.5 inch)
Spray Rate/Build Up 0.058 mm (0.0023 inch)/pass 0.058 mm (0.0023 inch)/pass
Rotation Speed of Part (RPM) RPM varies depending on diameter (42 RPM to 212 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/Mill
Part/Cutter Rotation Roughing 50 SMPM (150.00 SFPM)
Part/Cutter Rotation Finishing 75 SMPM (250.00 SFPM)
Coolant Oil base synthetic - 40:1 ratio

Traverse Speed 0.30 mm (0.012 inch) per revolution

Depth of Rough Cut 0.51 mm (0.020 inch) per side max.
Depth of Finish Cut 0.25 mm (0.010 inch) per side max.

Flame Spray Equipment and Procedure

Table 30
Flame Spray Equipment
Maximum Surface Texture 3.5 µm (137.8 µinch)
Reason for Spraying Wear, bearing failure
Mating Part Contact Area & Material Bearing race
Oerlikon Metco Equipment Type 6PII by Oerlikon Metco
Oerlikon Metco Material Oerlikon Metco 453
Finish Thickness As Required
Finishing Allowance 0.51 mm to 0.64 mm (0.020 inch to 0.025 inch) per side
Spray Angle 90°
Substrate Pre-Heat Temperature 66° C (150° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed 148° C (300° F)
Auxiliary Cooling If desired
Rotation/Traverse Device Lathe or headstock/tailstock arrangement, rotary 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

Table 31
Flame Spray Process
Flame Spray Process (6P) Procedure Check List
Clean Part Degrease in hot caustic solution
Undercut To "tru-up" surface
Chamfer If required - 1.0 mm (0.039 inch) x 45°
Remove Oxide Use fiber flap brush; 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 24 mesh aluminum oxide
Blast Air Pressure 690 kPa (100.0 psi)
Blast Nozzle to Work Distance 51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask Remove mask, make sure that surface is clean
Mask for Spray Oerlikon Metco Antibond or blue layout dye
Spray Equipment Type 6PII by Oerlikon Metco Hand Held Thermo Spray System
Auxiliary Cooling If desired
Nozzle 6P-C7A-K "K" Nozzle
Air Capacity/Pressure 6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure 210 kPa (30.0 psi)
Oxygen Flow 1190 L/h (42.0 cfh)
Fuel Gas Pressure 100 kPa (15.0 psi)
Fuel Gas Flow 1415 L/h (50.0 cfh)

Carrier Gas Pressure 380 kPa (55.0 psi)

Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build Up 5.5 kg (12 lb) per hour or 90 gm (3.2 oz) per min
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed of Part (RPM) RPM varies depending on diameter
Rotation Speed of Part (SFPM) 91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun (SFPM) 15.24 SMPM (50.000 SFPM)
Gun Fixturing Method Machine mount or hand held
Top Coat/Thickness 0.10 mm to 0.15 mm (0.004 inch to 0.006 inch) per pass
Finishing Equipment Lathe/Mill
Part/Cutter Rotation (SFPM) 91.4 SMPM (300.00 SFPM)
Traverse Speed 0.05 mm to 0.10 mm (0.002 inch to 0.004 inch) per revolution
Depth of Rough Cut 0.38 mm to 0.51 mm (0.015 inch to 0.020 inch) per side
Depth of Finish Cut 0.25 mm to 0.38 mm (0.010 inch to 0.015 inch) per side
Additional Finish Method Emery cloth for desired finish

Bearing Journal Thermal Spray Procedures

Part Description

Table 32
Part Description
Base Metal 1026 Mod, or Ductile Iron
Hardness

Arc Spray Equipment and Procedure

Table 33
Arc Spray Equipment
Maximum Surface Texture 1.6 µm (63.00 µinch)
Reason for Spraying Wear or grooving
Mating Part Contact Area & Material Bearing
Arc Spray Equipment Type Smart Arc by Oerlikon Metco,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 Spraying Not to Exceed 148° C (300° F)
Auxiliary Cooling Filtered shop air
Rotation/Traverse Device Lathe or headstock/tailstock arrangement, rotary turntable
Rotation Speed 92.0 SMPM (300.00 SFPM)
Surface Preparation Method Undercut and Grit blast
Equipment Required Turn (Horizontal or Vertical) Lathe
Recommended Cutting Tool ISCAR DNMG 432TFIC507
Blast Media Recommendation Pressure Type Only (Aluminum Oxide Grit)

Table 34
Arc Spray Procedure Check List
Clean Part Degrease in hot caustic solution
Undercut To "tru-up" surface
Chamfer If required - 1.0 mm (0.039 inch) x 45°

Remove Oxide Use fiber flap brush or Clean/strip disc

Clean Spray Area Commercial degreaser
Mask for Grit Blaster Duct tape
Grit Blast Equipment Pressure type only
Grit Type and Size 20 mesh aluminum oxide
Blast Air Pressure 690 kPa (100.0 psi)
Blast Nozzle to Work Distance 51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask Remove mask material, make sure that surface is clean
Mask for Metal Spray Anti-Bond or Blue Layout Dye
Metal Spray Equipment Type Smart Arc by Oerlikon Metco TAFA
Consumable (Bond coat) TAFA 75B TAFA 75B
Clamp Pressure 275 kPa (40 psi)
Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 30V 30V
Amps 125 Amps 150 Amps
Gun to Work Distance (Standoff) 128 mm (5.0 inch) 128 mm (5.0 inch)
Spray Rate/Bond Pass 0.038 mm (0.0015 inch)/pass 0.038 mm (0.0015 inch)/pass
Consumable (Topcoat) TAFA 30T TAFA 30T
Clamp Pressure 275 kPa (40 psi)
Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 31V 31V
Amps 150 Amps 175 Amps
Gun to Work Distance (Standoff) 166 mm (6.5 inch) 166 mm (6.5 inch)
Spray Rate/Build Up 0.058 mm (0.0023 inch)/pass 0.058 mm (0.0023 inch)/pass
Rotation Speed of Part (RPM) RPM varies depending on diameter
Rotation Speed of Part 92.0 SMPM (300.00 SFPM)
Traverse Rate of Gun 11.0 SMPM (40.00 SFPM)
Gun Fixturing Method Machine mount or hand held
Finishing Equipment Lathe or Horizontal Mill
Part/Cutter Rotation Roughing 50.0 SMPM (150.00 SFPM)
Part/Cutter Rotation Finishing 75.0 SMPM (250.00 SFPM)
Coolant Oil base synthetic - 40:1 ratio
Traverse Speed 0.30 mm (0.012 inch)
Depth of Rough Cut 0.51 mm (0.020 inch)
Depth of Finish Cut 0.25 mm (0.010 inch)

Flame Spray Equipment and Procedure

Table 35
Flame Spray Equipment
Maximum Surface Texture 1.6 µm (63.00 µinch)
Reason for Spraying Wear or grooving
Mating Part Contact Area & Material Bearing
Metco Equipment Type 6P-II by Oerlikon Metco
Metco Material Metco 453
Finish Thickness As Required
Finishing Allowance 0.51 mm to 0.64 mm (0.020 inch to 0.025 inch) per side
Spray Angle 90°

Substrate Pre-Heat Temperature 66° C (150° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed 148° C (300° F)
Auxiliary Cooling Filtered shop air
Rotation/Traverse Device Lathe or headstock/tailstock arrangement, rotary turntable
Rotation/Traverse Device 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

Table 36
Flame Spray Process (6P) Procedure Check List
Clean Part Degrease in hot caustic solution
Undercut To "tru-up" surface
Remove Oxide Use fiber flap brush or Clean/strip disc
Clean Spray Area Metco cleaning solvent or equivalent
Mask for Blast Duct Tape
Blast Equipment Pressure type only
Grit Type and Size 24 mesh Aluminum Oxide
Blast Air pressure 690 kPa (100.0 psi)
Blast Nozzle to Work Distance 51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask Remove mask, make sure that surface is clean
Mask for Spray Metco Antibond or Blue Layout Dye
Spray Equipment Type 6P-II Hand Held Thermo Spray System by Oerlikon Metco
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 g (3.2 oz) per min
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed of Part (RPM) RPM varies depending on diameter
Rotation Speed of Part 91.4 SMPM (300.000 SFPM)
Traverse Rate of Gun 15.24 SMPM (50.000 SFPM)
Gun Fixturing Method Machine mount or hand held
Top Coat/Thickness 0.10 mm to 0.15 mm (0.004 inch to 0.006 inch) per pass
Finishing Equipment Lathe or Horizontal Mill
Part/Cutter Rotation 91.4 SMPM (300.00 SFPM)
Traverse Speed 0.05 mm to 0.10 mm (0.002 inch to 0.004 inch) per revolution
Depth of Rough Cut 0.38 mm to 0.51 mm (0.015 inch to 0.020 inch) per side
Depth of Finish Cut 0.25 mm to 0.38 mm (0.010 inch to 0.015 inch) per side
Additional Finish Method Emery cloth for desired finish

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 Testing (VT), Liquid Penetrant Testing
(PT), Dry / Wet Magnetic Particle Testing (MT), and Ultrasonic Testing (UT).

Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, Dry/ Wet MT, and UT are
methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most
versatile. For example, the PT method can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using the
Wet MT is more accurate. Refer to Table 37 for advantages and disadvantages and Table 38 for standards and requirements for these NDT methods.

Table 37
Crack Detection Methods Advantages and Disadvantages
Detection Method Advantages Disadvantages
- Least Expensive
- Limited to surface-only defects.
- Detects most damaging defects.
Visual Testing (VT) - Requires inspectors to have broad knowledge of welding and fabrication in
- Immediate Results
addition to Non-Destructive Testing (NDT).
- Minimum part preparation
- Inexpensive
- Least Sensitive
Liquid Penetrant - Minimal Training
- Detects surface cracks only.
Testing (PT) - Portable
- Rough or porous surfaces interfere with test
- Works on nonmagnetic material.
- Portable
Dry Magnetic Particle - Fast/Immediate Results - Works on magnetic material only.
(MT) - Detects surface and subsurface - Less sensitive than Wet Magnetic Particle Testing (MT).
discontinuities
- More sensitive than Liquid Penetrant
- Requires power for light.
Wet Magnetic Particle Testing (PT).
- Works on magnetic material only.
(MT) - Detects subsurface as much as
- Liquid composition and agitation must be monitored.
0.13 mm (0.005 inch).
- Most Sensitive
- Detects deep material defects. - Most Expensive
Ultrasonic Testing
- Immediate Results - Requires operator training and certification.
(UT)
- Wide range of materials and thickness - Surface must be accessible to probe
can be inspected

Table 38
Applicable Crack Detection Standards
Minimum
Acceptance Required
Detection Method Standard
Criteria Personnel
Qualifications
EN-ISO 5817 EN-ISO 5817 - Level B EN-ISO 9712
Visual Testing (VT)
AWS D1.1 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A
EN-ISO 3452 EN-ISO 23277 EN-ISO 9712
Liquid Penetrant Testing (PT)
ASTM E165 AWS - D1.1 ANSI-ASNT SNT-TC-1A
EN-ISO 17638 EN-ISO 23278 - Level 1 EN-ISO 9712
Magnetic Particle Testing (MT)
ASTM E709 AWS D1.1 - Table 6.1 ANSI-ASNT SNT-TC-1A
EN-ISO 17640 - Level B EN-ISO 11666 Technique 2 - Level 2 EN-ISO 9712
Ultrasonic Testing (UT)
AWS D1.1 AWS D1.1 - Class A - Table 6.3 ANSI-ASNT SNT-TC-1A

Visual Surface Inspection (VT)

Illustration 63 g06124166
Example of Visual Testing (VT) Tooling
(A) Flashlight (or adequate light source)
(B) Magnifying Glass
(C) Tape Measure (or other measuring device)
(D) Inspection Mirror

Refer to Tooling and Equipment Table 3 for part numbers.

Components and welds that are to be tested using PT, MT, or UT shall first be subject to Visual Testing (VT). VT is often the most cost-effective
inspection method and requires little equipment as seen in Illustration 63. 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

Refer to Tooling and Equipment Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetration Oil: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the
visibility of the penetrating oil indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

Illustration 64 g06084048
Typical example of pre-cleaning the testing area.

1. Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe the area to be tested with a solvent dampened
cloth to remove remaining dirt and allow the area to dry. Remove paint where there are visible cracks using paint remover or a wire brush.

Illustration 65 g06084053
Typical example of applying penetrating oil to areas to be tested.

2. Apply penetrating oil by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrating oil to soak. After the penetrating oil has
been allowed to soak, remove the excess penetrating oil with clean, dry wipe.

Illustration 66 g06084060
Typical example of removing penetrating oil with a cloth.

3. The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.

Illustration 67 g06084070
Typical example of applying the developer.

4. Before using developer, ensure that the developer is mixed thoroughly by shaking the container. Hold the container approximately
203 - 305 mm (8 - 12 inch) away from part. Apply an even, thin layer of developer over the area being tested. A few thin layers are a better
application method than one thick layer.

Illustration 68 g03773759
Typical example of cracks found during Liquid Penetrant Testing (PT).

5. Allow the developer to dry completely for 10 to 15 minutes before inspecting for cracks. Defects will show as red lines in white developer
background, refer to Illustration 68. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 69 g06085930
(A) Indications shown by Dry Magnetic Particle Testing (MT).
(B) Electromagnetic Yoke
(C) Dry Powder Bulb

1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications.
The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as
sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of
contamination will determine further use of the powder.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not
performing.

4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around
the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the
yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting
force of at least 4.5 kg (10 lbs).

5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should
also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions
of the magnetic field are created.

6. Observe particles and note if any clusters of particles appear revealing an indication.

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MT)

Materials and Equipment

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 70 g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MT).
(B) Electromagnetic Yoke
(D) Ultraviolet Lamp

Illustration 71 g06003178
Pear Shaped Centrifuge Tube

1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by
spraying.

2. Concentration:

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 71. 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.

Illustration 72 g03536210

3. For case hardened and ground surfaces:

◦ Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is
applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity
resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be
used. See Illustration 72 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 37 for crack detection standards.

Refer to Tooling and Equipment Table 3 for part numbers.

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

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

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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 19-06-2023

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