Rear Spindle

By NPR - SEBF8083 - Inspection and Salvage of Wheel Spi...
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Inspection and Salvage of Wheel Spindles for all Off-

Highway Trucks{4201, 4205}
SMCS - 4201; 4205
Off-Highway Truck/Tractor: All
Introduction
Table 1
Summary of Changes in SEBF8083-10
Added 190-6092 and 190-6091 dimensions to Table 7, Table 13, and Table 16.
Added 247-0895 and 244-7765 dimensions to Table 17.
Revised Introduction.
2010 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers
only. Unauthorized use of this document or the proprietary processes therein without
permission may be violation of intellectual property law.
This Reuse and Salvage Guideline contains the necessary information in order 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 in order 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 questions or additional information concerning this guideline, submit a form for
feedback in the Service Information System. In order to address an urgent issue, please use
the following resources in order to communicate your request to Caterpillar Repair Process
Engineering:
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp... 12/01/02
By NPR - SEBF8083 - Inspection and Salvage of Wheel Spi... Page 2 of 64
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Caterpillar Technical Representative
Knowledge Network
Summary
This guideline provides the procedures that are necessary to determine the reusability for
front spindles and rear spindles on Off-Highway Trucks. This guideline includes
information about the salvage of wheel bearing journals of spindles on Off-Highway
Trucks. This guideline also explains the procedure to salvage front spindles and rear
spindles on Off-Highway Trucks. Specifications are provided for both front spindles and
rear spindles.
This guideline contains the latest standards of engineering, which will help minimize
owning and operating costs. A part can be expected to reach the next Planned Component
Repair if the part meets the specifications in this guideline and if the part is used in the
same application. Use this guideline in order to determine whether a part should be reused.
Do not install a part that is not reusable. During reconditioning, correct any condition that
might have caused the original failure.
Important Safety Information

Follow all safety warnings. Most accidents that involve product operation, maintenance, or
repair are caused by failure to observe safety warnings. An accident can often be avoided
by recognizing potentially hazardous situations before an accident occurs. Personnel should
be properly trained in order to perform maintenance, repair or operate any machine.Safety
precautions and warnings are provided this instruction and on Caterpillar products. These
warnings should be observed before performing any procedures. Caterpillar cannot
anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are not all inclusive.
The hazards are identified by the "Safety Alert Symbol" which is followed by a "Signal
Word" such as "DANGER", "WARNING" or "CAUTION". The "WARNING" Safety
Alert Symbol is shown in Illustration 1.
Illustration 1 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. You must determine that the tools, procedures,
work methods, and operating techniques are safe. You must determine that the
operation, lubrication, maintenance, and repair procedures will not damage the
machine. Also, you must 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.
Warnings
Personal injury or death can result from lifting a

heavy assembly.
The heavy assembly can fall if using an incorrect hoist

to lift the load.
Be sure the hoist has the correct capacity to lift a

heavy assembly. Approximate weight of the assembly
is given below.
The approximate weight of 247-0870 Spindle Assembly is 3647 kg (8040 lb).
References
Table 2
References
Media Number
Title
SERF8473 "Arc Spray Guide- CD-Rom"

SERF8705 "HVOF Spray Guide- CD-Rom"
"Procedure to Inspect and Repair Wheels Used on Off-Highway
SEBF8443
Trucks"
Checklist for Inspection and Salvage of Wheel Spindles

Reuse Inspection
Table 3
Critical Available Procedures
Type of Check
Features for Salvage
Entire spindle Magnetic particle inspection and dye penetrant
Yes
for cracks
Splines Measure Outside Diameter over pins No (1)
The hardness for each journal must be at a
Rockwell rating of at least 30N 64. (Rockwell C
45)
Bearing The tolerance of the OD for each journal is
Yes
journals + 0.025 - 0.050 mm (+ 0.0010 - 0.0020 inch).
The alignment of each journal must be
measured to a tolerance of
0.025 mm ( 0.0010 inch).
(1)
Acceptable core for Remanufacturing
Salvage
Table 4
Critical Features
Operation
Repair with Arc Spray or HVOF Refer to Table 3 for the hardness.
Bearing journals
Machine the journals to size. Alignment must be measured to the
value in Table 3.
Protective Equipment, Tools and Materials Needed

The following tools will be required to perform the repair procedures in this guideline.
Table 5
Inspection Application Comments

Suitable
lifting device Handling or moving spindle
Rotary wire Cleaning all mounting

brush surfaces
Cleaning
Washing the spindle
System
Magnetic
Inspection of cracks in a
particle
spindle
detector kit
Dial indicator Taking measurements during
gp inspection
Outside Taking measurements of
micrometer bearing journals and splines
Taking measurements of the
Inside
dimension between pins on an
micrometer
internal spline
Use a 30N Rockwell tester. You may
Measure the hardness of
also use a C rated Rockwell tester. The
bearing journals. The
tester must not leave marks. The
Hardness hardness must be at a
Krautkramer Branson MIC 10 is the
tester Rockwell of at least 64 on the
recommended tester for heat-treated
30N scale. This is equivalent
materials, HVOF coatings, and Arc
to 45 Rockwell C.
Spray coatings.
Salvage
Arc Spray
system or After the thermal spray process, check
Restoring bearing journals
HVOF system the hardness of the bearing journals.
Adequate Machining and inspection of

lathe bearing journals
Identification of Spindle Type

Illustrations 2, 3, and 4 show the typical configuration of front wheels on Off-Highway
Trucks. Illustrations 5, 6, and 7 show a typical configuration for a rear wheel. Use the
following illustrations in order to determine the type of spindle.
Typical front spindle
Typical front spindle
Type 3 front spindle. This spindle is used for all Off-Highway Trucks.
Typical rear spindle
Type 1 two-piece rear spindle. This spindle is used by the 773. This spindle is also used by some of the
first 773B Off-Highway Trucks.
Type 2 rear spindle. This spindle is used by all other Off-Highway Trucks.
Identification of Areas that Wear
The area between the bearing and the spindle (arrows) can encounter wear.
Cleaning
All spindles should be cleaned prior to inspection. Clean irregularities from all surfaces. A
surface irregularity can hide the indication of an unacceptable defect. Make sure that all
surfaces are free from contaminants such as rust, grease, oil, burrs, and paint.
Inspection
By NPR - SEBF8083 - Inspection and Salvage of Wheel S... Page 10 of 64
General Guidelines
Inspect the spindle before the salvage procedure. The spindle should be inspected
immediately after disassembly and cleaning. To prevent a failure, you must inspect each of
the following critical areas of a spindle.
Entire Spindle Inspect the spindle for cracks. Use either a magnetic particle or a
liquid dye penetrant in the inspection process. An internal crack can lead to a failure
after a salvage procedure. Do not install a cracked spindle.
Splines A cracked spline must not be salvaged. A spline that does not meet the
dimensional requirement cannot be salvaged. Because splines transfer high loads, you
must thoroughly inspect each spline for cracks. Measure the average dimension over
pins or the average dimension between pins in order to determine wear.
Bearing Journals Measure the surface hardness and the outside diameter for each
journal. Bearing journals may be salvaged by using Arc Spray or by using High
Velocity Oxygen Fuel (HVOF).
Mounting Flange Bolt Holes These bolt holes may experience damage if bolts are
loose during operation. Inspect each bolt hole for deformation. You may salvage a
deformed bolt hole by welding the bore and machining the bore.
Always use proper lifting devices for the safety of the operator. Prevent damage to
machined surfaces by using the correct lifting equipment.
Visual Inspection
Wheel Bearing Journals
A wheel bearing journal can be visually inspected with the unaided eye. During an
inspection, the best results can be achieved with the use of a magnifying glass and a strong
light source. Sunlight is the best light source. If it is difficult to distinguish small scratches
from cracks, use either a liquid dye penetrant or a magnetic particle inspection.
Normal Wear
The following photos show both inner wheel bearing journal and outer wheel bearing
journal. However, the criteria for reusing either wheel bearing journal is identical.
The outer journal surface in this illustration has just been laser hardened. The shiny area (A) has been
buffed slightly in order to check the hardness.
USE AGAIN
This is a laser hardened inner journal that exhibits normal wear. Once the corrosion has been removed
from the surface, this part may be reused.
USE AGAIN
This is an inner journal that exhibits normal wear.
USE AGAIN
This inner journal exhibits light wear and light pitting (B) .
USE AGAIN
Surface Damage
In order to recondition the surface of a bearing journal, refer to CD-ROM, SERF8705,

"HVOF Spray Guide- CD-Rom".
This bearing journal surface exhibits smearing damage (C). Before you reuse the spindle, buff the
surface and verify the dimensions.
Refer to Tables 15, 16, or 17.
USE AGAIN
This is a magnified view of Illustration 13. Before you reuse the spindle, buff the surface and verify the
dimensions. Refer to Tables 15, 16, or 17.
USE AGAIN
This is an outer journal that exhibits bruising (D). A band of corrosion (E) is shown below the journal.
DO NOT USE AGAIN
This journal may be salvaged using CD-ROM, SERF8705, "HVOF Spray Guide- CD-Rom".
Note: If corrosion (E) is the only damage, the spindle may be reused after you buff the
corrosive area.
This outer journal exhibits scratching and spalling damage.
DO NOT USE AGAIN
This is an outer journal that exhibits heavy damage from spalling.
DO NOT USE AGAIN
This outer journal has a layer of thermal spray material that is mostly gone.
DO NOT USE AGAIN
This is an inner journal that exhibits scratching and spalling damage.
DO NOT USE AGAIN
This inner journal has a layer of thermal spray material that has started to flake off. The bond between
the journal and the thermal spray material failed.
DO NOT USE AGAIN
The scalloped edge on the wheel has caused the inner bearing journal to wear a round groove into the
spindle.
USE AGAIN
The depth of the groove must not exceed 2.000 mm (0.0787 inch). Buff the surface in order to eliminate
sharp edges or grooves.
Brake Anchor Flange
This spindle has cracked at the radius near the brake anchor flange.
DO NOT USE AGAIN
This illustration shows a different view of the crack.
DO NOT USE AGAIN
Porosity of Spindles
These criteria for inspection have been written in an effort to assist in determining the
acceptability of parts by using visual inspection. The spindles are divided into multiple
quadrants for inspection in Illustration 26.
Note: The neutral axis is the axis that runs through AETA Hole (AA) and Lubrication Hole
(BB). See Illustrations 24 and 25 for the locations of these holes.
Note: The 797 models have a lubrication hole, but the 797 models do not have an AETA
hole. The neutral axis for these models is the axis that runs through Lubrication Hole (BB).
(AA) AETA hole
(BB) Lubrication hole
(AA) AETA hole
(BB) Lubrication hole
Areas of Inspection
Top view of typical wheel spindle that is separated into four quadrants for inspection
(1) Lubrication hole
(2) Neutral axis
(3) Angle (45 degrees)
Length (X) is slightly longer than the thickness of the retainer that sets the location of the inner bearing.
(X) Length (Table 6)
Cast Surface
The cast surface shall be free from scale, cracks, hot tears, and any sand that is adhering to
the surface.
Area (4)
(4) Area
Area (4) is the area around the entire circumference of the spindle with Length (X) .
No visible defects are allowed.
Area (5)
(5) Area
Area (5) is the area around the entire circumference of the outer journal.
No more than one 3.0 mm (0.12 inch) indication (diameter and depth) is allowed in a
2500 mm 2 (3.9 in 2).
No more than two indications of the above size are allowed in the entire region.
No more than 15 total indications are allowed in this region.
Area (6)
(6) Area
Area (6) is the area on both the top and bottom quadrants of the spindle but excluding the
inner journal and the outer journal. Area (6) extends from Length (X) to the end of the
spindle.
2500 mm 2 (3.9 in 2) area.
No more than four indications of above size are allowed on the entire area.
Area (7)
(7) Area
Area (7) is the area around Neutral Axis (2), or the area on both the side quadrants of the
spindle but excluding the inner journal and the outer journal. Area (7) extends from Length
(X) to the end of the spindle.
2500 mm 2 (3.9 in 2) area.
No more than four indications of above size are allowed on the entire area.
Area (8)
(8) Area
Area (8) is the area on both the top and bottom quadrants of the inner journal.
2500 mm 2 (3.9 in 2) area.
No more than three indications of the above size are allowed in the entire region.
Area (9)
(9) Area
Area (9) is the area on both of the side quadrants of the inner journal.
2500 mm 2 (3.9 in 2) area.
No more than two indications of the above size are allowed in the entire region.
Table 6
Parameters for Acceptable Porosity
Model Length (X) (1)
777
40 mm (1.6 inch)
785
785B
68 mm (2.7 inch)
785C
789
789B
68 mm (2.7 inch)
789C
793
793B
793C 68 mm (2.7 inch)
793D
797
797B 68 mm (2.7 inch)
(1)
Length (X) is measured from the flange face.
Example of porous indications
Splines
Perform a complete inspection of the spline before you proceed with the repair procedure.
During an inspection, the best results can be achieved with the use of a magnifying glass
and a strong light source. Sunlight is the best light source. If it is difficult to distinguish
small scratches from cracks, use either a liquid dye penetrant or a magnetic particle
inspection.
Inspect every spline on each spindle. If a damaged spline is found, recheck the spline on
mating parts. Then, inspect the teeth that are 180 degrees from the damaged splined tooth
for possible bending fatigue.
Crack Inspection
Before you check for cracks, clean the spline. Refer to Reuse and Salvage Guideline,
SEBF8193 in order to perform a detailed inspection of cracks.
Useful Life of Splines

Because a final drive spline is heavily loaded, you must inspect each spline very carefully.
Use the criteria in this guideline in order to make sure that each spline is reusable.
Typical Sequence in the Failure of a Spline

When you inspect a spline, you must determine whether the damage will progress into a
failure before the next scheduled overhaul. Analyze the application and spline size for each
truck when you make this determination.
There are two typical sequences for a failure:
Misalignment can cause spline wear. Spline wear can lead to a fracture.
A fatigue crack can cause a fracture.
Wear and Misalignment

There is normally a small amount of relative motion between meshing spline teeth. Uneven
contact patterns on the spline teeth are the result of misalignment of one or both of the
meshing splines. Splines that are misaligned do not fully engage. This means that only a
portion of each tooth is carrying the full load. If the hub and the spindle are not aligned, the
spline teeth will not mesh correctly. This situation can place high contact pressures on a
portion of the teeth. Misalignment can cause high contact pressure and relative movement.
Eventually, spline wear and fretting corrosion will appear as damage on the surface.
Misalignment can be identified by the uneven contact pattern on the spline teeth.
If any spline displays uneven contact patterns, be sure to check for misalignment and
correct the cause of the problem. The spline could be misaligned, if any of the following
are worn or damaged.
Bearings
Carrier bores
Thrust faces of a carrier
Carrier shafts
Do not reuse a spline with damage from misalignment. Even if you correct the cause of
misalignment, the previous abnormal wear will not permit full tooth contact. Correct the
cause of misalignment. Then install a new spline.
Normal Wear
This internal spline shows signs of full contact and even wear.
USE AGAIN
The spline shows signs of even loading and full contact.
USE AGAIN
Even though the area has a deep indentation, the spline is not cracked.
USE AGAIN
The spline in this illustration has an external wear step. This spline is reusable because the
measurements are within the required specification. Fretting corrosion is also apparent due to lack of
lubrication. Fretting should not progress if the spline is reused.
USE AGAIN
Damage of Spline Teeth
A tooth on this spline is missing and the adjacent teeth are heavily damaged.
DO NOT USE AGAIN
This spline has a crack which began in the root. The crack has progressed into the adjacent splines.
DO NOT USE AGAIN
Pitting and Fretting
This spline shows heavy pitting.
DO NOT USE AGAIN
This spline has heavy fretting corrosion.
DO NOT USE AGAIN
Fatigue Cracks
Operational loads create tensile stress in the fillet area on the loaded side of a tooth. With
enough high loads and cycles, these stresses can cause fatigue cracks. A fatigue crack will
develop until the tooth weakens enough to separate from the parent metal.
A bending fatigue can cause several spline teeth to break. The spline could then fail.
Cracking can also occur between the root of the tooth and a bolt hole or inside diameter of
the part.
Crack extending from the spline into bolt hole.
DO NOT USE AGAIN
The crack extends from the root of the tooth to the inside diameter of the part.
DO NOT USE AGAIN
Reusability of Splines
This section provides the procedures that are necessary for you to measure both internal
splines and external splines. This section will help you to calculate these measurements.
Then, these results can be used to determine reusability of both internal splines and external
splines on all Off-Highway Trucks.
Measuring Procedure
For the measurement of an external spline, take three measurements over pins. For
each of the three dimensions, measure the highest external point over two pins that are
180 degrees opposite of each other.
Average the three dimensions in order to produce the average dimension over pins.
For the measurement of an internal spline, take three measurements between pins. For
each measurement, take the closest internal point between two pins that are 180
degrees opposite of each other.
Average the three dimensions in order to produce the average dimension between pins.
Compare these measurements to Table 7 in order to determine the spline wear.
This external spline exhibits a typical wear step.
This internal spline exhibits a typical wear step.
For this procedure, each type of spline will require the use of a specific pin set. There are
three pin sets for the measurement of splines on Off-Highway Trucks. Each pin set consists
of 6 pins. Each pin is machined to a specific dimension. Care must be taken in order to
precisely machine these pins to the specification due to the close tolerances of the splines.
Make the pins out of SAE1020 steel. Use the dimension for the pin diameter in Table 7 to
precisely machine each pin for the specific pin set. Magnetize each pin so that the pins will
stay in place during the process of measurement. You may also use a rubber band to secure
the pins. Refer to Illustration 47.
To measure an external spline, calculate the average for the three measurements over pins.
To measure an internal spline, calculate the average for the three measurements between
pins. Use the following procedure to determine the maximum allowable spline wear.
Use an inside micrometer to measure internal splines. Use an outside micrometer to

measure external splines. To obtain accurate results, you must have a thorough working
knowledge of the use of both inside and outside micrometers.
Pins must be 60 degrees from other pins. Refer to Illustration 48 and Illustration 51.
Place pins at 60 degree intervals. A rubber band is used to secure the pins.
The measurement of an external spline is shown here. Pins are located at 60 degree intervals.
Take three measurements (A), (B), and (C) over pins that are 180 degrees across from each other. The
outside micrometer must be positioned in order to measure the highest two points over the pins. The
next section will demonstrate the correct way to calculate the average dimension over pins.
The measurement of an external spline is shown here. Pins are located at 60 degree intervals.
Internal spline measurement is similar to external spline measurement.
Take measurements between pins that are 180 degrees across from each other. The inside micrometer
must be positioned in order to measure the closest two points between the pins. Record measurements
(A), (B), and (C). The next section will demonstrate the correct procedure to calculate the average
dimension between pins.
You must also verify that the spline is not out of round. This can be done by taking the
maximum difference between the high pin and the low pin. The next section provides
examples for obtaining this measurement. This measurement is a critical measurement

which must be calculated in order to ensure that the spline can evenly transfer a load.
Measurement Examples
Internal Spline
Place pins at 60 intervals on the spline. The location of the 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.
The following steps should be taken in order to measure an internal spline.
1. Take measurements at location (A), (B), and (C). Refer to Illustration 52. The
measurements in the following list are provided as an example.
Dimension (A) is 242.000 mm (9.5275 inch).
Dimension (B) is 242.200 mm (9.5354 inch).
Dimension (C) is 242.400 mm (9.5433 inch).
2. Once measurements (A), (B), and (C) are obtained, add the measurements together.
" (A) + (B) + (C) = 726.600 mm (28.6062 inch)"
3. Divide this sum by 3 in order to obtain the average. The result is 242.200 mm (9.5354
inch).
4. Because this average is less than the specified dimension of 242.816 mm (9.5597
inch), the spline may be reused.
5. Calculate the difference between the high dimension and the low dimension. This
measurement indicates whether the splines are out of round. Never install a warped
spline. A load cannot be distributed evenly on a spline that is out of round. Teeth on a
warped spline can crack due to excessive stress. The excessive stress is caused from an
uneven load distribution on the splines. The maximum difference between the high
dimension and the low dimension is specified in Table 7. Do not reuse the spline if the
measurement exceeds this dimension.
6. Subtract the low measurement from the high measurement. The high dimension
242.400 mm (9.5433 inch) minus the low dimension 242.000 mm (9.5275 inch) is
0.400 mm (0.0157 inch). Table 7 designates a maximum dimension between the high
dimension and the low dimension of 0.635 mm (0.0250 inch).
The result 0.400 mm (0.0157 inch) is less than the specified maximum difference between
the high dimension and the low dimension. Therefore, the spline can be reused.
If the spline does not meet both specifications, do not reuse the spindle. . An internal
spline must pass both of the following tests in order to be used again.
Maximum dimension between pins
Maximum difference between the high dimension and the low dimension
External Spline
Place pins at 60 intervals on the spline. The location of the pins at 60 intervals is critical
to the formula. These three locations will provide information about the wear of the part.
Refer to Illustration 48.
The following steps show the calculations that are required to check the measurements for
an external spline. To review the specifications for the 179-0745 spindle , refer to Table 7.
1. Take measurements at location (A), location (B), and location (C). The measurements
in the following list are provided as an example.
Dimension (A) is 416.250 mm (16.3878 inch).
Dimension (B) is 416.500 mm (16.3976 inch).
Dimension (C) is 416.750 mm (16.4074 inch).
2. Once measurements (A), (B), and (C) are obtained, add the measurements together.
"Dimension (A) + (B) + (C) = 1249.500 mm (49.1928 inch)"
3. Divide this sum by 3 in order to obtain the average. The result is 416.500 mm (16.3976
inch).
4. Because this average is greater than 416.035 mm (16.3793 inch) (the specification for
the minimum dimension over pins), the spline wear is acceptable.
5. Calculate the difference between the high measurement 416.750 mm (16.4074 inch)
and the low measurement 264.899 mm (10.4291 inch).
"416.750 mm (16.4074 inch) - 416.250 mm (16.3878 inch) = 0.500 mm (0.0197

inch)"
The difference between the high dimension and the low dimension indicates whether
the splines are out of round. Never install a warped spline. A load cannot be distributed
evenly on a spline that is out of round. Teeth on a warped spline can crack due to
excessive stress. The excessive stress is caused from an uneven load distribution on the
splines. The difference between the high measurement and the low measurement will
help to determine if the part can be used again.
The maximum dimension between the high dimension and the low dimension is 0.416
mm (0.0164 inch). Refer to Table 7 for this dimension. Because the actual difference
0.500 mm (0.0197 inch) is greater than the allowable maximum, This spline is
elliptical. DO NOT USE AGAIN
If the spline does not meet both specifications, do not reuse the spindle.. An external
spline must pass both of the following tests in order to be used again.
Minimum dimension over pins
Maximum difference between the high dimension and the low dimension
Table 7
Reuse Dimensions for Splines on Off-Highway Truck Spindles.
Maximum
Maximum
Part Minimum Difference Between
Model Pin Dimension
Number Dimension the High Dimension
Diameter Between Pins
Over Pins and the Low
Dimension
mm (in) mm (in) mm (in) mm (in)
797B 247-0870 7.938 mm 563.151 mm 562.588 mm

0.563 mm (0.0222
(0.3125 (22.1713 (22.1491 inch)
inch)
inch) inch)
139-7622 7.938 mm 563.151 mm 562.588 mm

797 0.563 mm (0.0222
(0.3125 (22.1713 (22.1491 inch)
inch)
inch) inch)
247-0870 7.938 mm 563.151 mm 562.588 mm

797 0.563 mm (0.0222
(0.3125 (22.1713 (22.1491 inch)
inch)
inch) inch)
793C
179-0745 6.350 mm 416.451 mm 416.035 mm
793D 0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
793D 190-6092 8 mm 426.451 mm 426.025 mm

0.426 mm (0.01677
(0.31496 (16.78938 (16.77260
inch)
inch) inch) inch)
793C
152-8888 6.350 mm 416.451 mm 416.035 mm
793D 0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
793C 139-9187 6.350 mm 416.451 mm 416.035 mm

0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
793C 125-6605 6.350 mm 416.451 mm 416.035 mm

0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
793B 125-6605 6.350 mm 416.451 mm 416.035 mm

0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
793B 113-6048 6.350 mm 416.451 mm 416.035 mm

0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
793B 106-6527 6.350 mm 416.451 mm 416.035 mm

0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
793B 8X-1067 6.350 mm 416.451 mm 416.035 mm

0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
8X-1067 6.350 mm 416.451 mm 416.035 mm

793 0.416 mm (0.0164
(0.2500 (16.3957 (16.3793 inch)
inch)
inch) inch)
789C 179-0743 4.763 mm 377.807 mm 377.429 mm

0.378 mm (0.0149
(0.1875 (14.8743 (14.8594 inch)
inch)
inch) inch)
789C 152-8886 4.763 mm 377.807 mm 377.429 mm

0.378 mm (0.0149
(0.1875 (14.8743 (14.8594 inch)
inch)
inch) inch)
789B 152-8886 4.763 mm 377.807 mm 377.429 mm

0.378 mm (0.0149
(0.1875 (14.8743 (14.8594 inch)
inch)
inch) inch)
789B 129-1526 4.763 mm 377.807 mm 377.429 mm

0.378 mm (0.0149
(0.1875 (14.8743 (14.8594 inch)
inch)
inch) inch)
789B 8X-8093 4.763 mm 377.807 mm 377.429 mm

0.378 mm (0.0149
(0.1875 (14.8743 (14.8594 inch)
inch)
inch) inch)
8X-8093 4.763 mm 377.807 mm 377.429 mm

789 0.378 mm (0.0149
(0.1875 (14.8743 (14.8594 inch)
inch)
inch) inch)
5T-5748 4.763 mm 377.807 mm 377.429 mm

789 0.378 mm (0.0149
(0.1875 (14.8743 (14.8594 inch)
inch)
inch) inch)
785C
152-8884 4.763 mm 316.880 mm 316.563 mm
785D 0.317 mm (0.0125
(0.1875 (12.4756 (12.4631 inch)
inch)
inch) inch)
785B 152-8884 4.763 mm 316.880 mm 316.563 mm

0.317 mm (0.0125
(0.1875 (12.4756 (12.4631 inch)
inch)
inch) inch)
785B
131-2524 4.763 mm 316.880 mm 316.563 mm
785D 0.317 mm (0.0125
(0.1875 (12.4756 (12.4631 inch)
inch)
inch) inch)
131-2524 4.763 mm 316.880 mm 316.563 mm

785 0.317 mm (0.0125
(0.1875 (12.4756 (12.4631 inch)
inch)
inch) inch)
6G-6574 4.763 mm 316.880 mm 316.563 mm

785 0.317 mm (0.0125
(0.1875 (12.4756 (12.4631 inch)
inch)
inch) inch)
777D 152-8882 4.763 mm 235.638 mm 235.402 mm

0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
777C 107-8540 4.763 mm 235.638 mm 235.402 mm

0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
777C 7I-5633 4.763 mm 235.638 mm 235.402 mm

0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
777B 7I-5633 4.763 mm 235.638 mm 235.402 mm

0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
777B 5T-3083 4.763 mm 235.638 mm 235.402 mm

0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
5T-3083 4.763 mm 235.638 mm 235.402 mm

777 0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
9D-9252 4.763 mm 235.638 mm 235.402 mm

777 0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
8X-9081 4.763 mm 235.638 mm 235.402 mm

777 0.236 mm (0.0093
(0.1875 (9.2771 inch) (9.2678 inch)
inch)
inch)
775D
775E 106-6520 4.763 mm 250.870 mm 250.619 mm
0.251 mm (0.0099
775F (0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
775B 106-6520 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
775B 7I-5445 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
775B 8W-7079 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773D
773E 106-6520 4.763 mm 250.870 mm 250.619 mm
0.251 mm (0.0099
773F (0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773B 106-6520 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773B 7I-5445 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773B 106-6520 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773B 8W-7079 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773B 5T-2997 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773B 5T-2378 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
773B 2G-3479 4.763 mm 250.870 mm 250.619 mm

0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
2G-3479 4.763 mm 250.870 mm 250.619 mm

773 0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
7D-2819 4.763 mm 250.870 mm 250.619 mm

773 0.251 mm (0.0099
(0.1875 (9.8768 inch) (9.8669 inch)
inch)
inch)
771D 5T-2993 4.763 mm 207.667 mm 207.459 mm

0.208 mm (0.0082
(0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
771C 5T-2993 4.763 mm 207.667 mm 207.459 mm

0.208 mm (0.0082
(0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
769D 5T-2993 4.763 mm 207.667 mm 207.459 mm

0.208 mm (0.0082
(0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
769C 5T-2993 4.763 mm 207.667 mm 207.459 mm

0.208 mm (0.0082
(0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
769C 2G-5549 4.763 mm 207.667 mm 207.459 mm

0.208 mm (0.0082
(0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
769B 5D-6357 4.763 mm 207.667 mm 207.459 mm

0.208 mm (0.0082
(0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
5D-1141 4.763 mm 207.667 mm 207.459 mm

769 0.208 mm (0.0082
(RH) (0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
5D-1142 4.763 mm 207.667 mm 207.459 mm

0.208 mm (0.0082
(LH) (0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
5D-6357 4.763 mm 207.667 mm 207.459 mm

769 0.208 mm (0.0082
(0.1875 (8.1758 inch) (8.1677 inch)
inch)
inch)
Welding Procedure for Cracks in the Rear Spindle of 773

through 793 OHT
The welding procedure in the next section can be used to repair cracks in the rear spindle
housing of a 773-793 OHT. The procedure consists of cleaning the spindle, inspection, and
preparation. Before the welding procedure, the spindle is preheated. After the welding
process, the spindle is postheated.
Welding Requirements
Qualification and Safety for the Welder
All welders must be qualified for fillet welding and groove welding according to the
current ANSI/AWS D1.1, D14.3, or Caterpillar Manufacturing Practice MC1000-105.
The welding operator must hold a current certification for this process. The welding
operator must have used this welding process during the last six months. The operator must
wear the appropriate equipment. The operator must also install all appropriate equipment.
All equipment must maintain the amount of fumes, heat, and UV radiation at a safe limit.
Characteristics of Welding Electrodes
Table 8
Welding Process and Consumables
Welding Process Type of Electrode Specification of AWS
Diameter
Dual Shield II 70
FCAW 1.60 mm (0.063 inch) E71T-1
Dual Shield 7000

FCAW 1.60 mm (0.063 inch) E71T-1
Dual Shield 7100

FCAW 1.15 mm (0.045 inch) E71T-1
Table 9
Welding Parameters (1)
Wire Feed Speed
Consumable Amperage Volts Polarity
mm/sec in/min
DS 7000 FCAW 76 180 275 28 Reverse
DS II 70 FCAW 76 180 275 28 Reverse
DS 7100 FCAW 76 180 275 28 Reverse
(1)
Use a shielding gas of C02 or 75% Argon/25% C02 at 0.992 cubic meters/hr (35 cubic feet/hr)
An alternative SMAW process may be used with the E10018- D2 (ANSI/AWS A5.5)
welding electrode. This electrode will produce a weld that has the following minimum
mechanical properties.
Table 10
E10018- D2 (ANSI/AWS A5.5)
Tensile Strength 703 MPa (102,000 psi)
Yield Strength 614 MPa (89,000 psi)
% Elongation
22%
51 mm (2.0079 inch)
Impact Toughness 25 ft.-lbs @ -60F (34J @ -51C)
Note: The E10018-D2 is a low hydrogen electrode. The electrode must be stored in an
electrode oven at a temperature of 120 C (248 F) at all times. If a E10018-D2 electrode
becomes damp, scrap the electrode or recondition the electrode to manufacturer's
specifications.
Each electrode size has a specified amperage for welding. This rating is specified in the
following Table (11).
Table 11
Diameter AMPS
(1/8 inch)
70-140
3.2 mm (0.13 inch)
(5/32 inch)
110-180
4.0 mm (0.16 inch)
(3/16 inch)
190-270
4.8 mm (0.19 inch)
Use the setting for DC electrode positive (DC reverse polarity) and remove the slag after
every pass. The length of the weld pass must not exceed two times the electrode diameter.
Cleaning
Clean all oil, grease, paint, and dirt from the weld area. Attach the welding ground cable
directly to the spindle. Protect all machined surfaces from sparks or spatter that can result
from welding, chipping, and/or grinding.
Inspection
Use a liquid dye penetrant and/or magnetic flux to inspect the spindle for cracks. With each
inspection method, it may be necessary to prepare the surface by removing any
irregularities. A surface irregularity can hide the indication of an unacceptable defect. Use
the following criteria to determine if the cracks can be repaired.
1. Cracks may not extend through the entire section. Cracks may not be deeper than the
dimensions in Table 12.
2. Cracks may not be longer than 203.2 mm (8.00 inch).
3. Do not weld cracks in area (A) in Illustration 53.
Preparation
Note: Be sure that the temperature of the base metal is at least 21 C (70.0 F). This
temperature must be maintained throughout the cutting process. Protect the piece from
drafts. This is especially important in cold weather.
1. Remove the crack. Use an air carbon arc torch.
2. After the crack has been completely removed, prepare the weld groove. Use a grinder
to create an angle on the sidewall of the gouged section.
Perform one of the following operations.
Any crack that has a depth of 38 mm (1.5 inch) or less is a small crack. To prepare
the groove for a small crack, grind a 30 degree angle on the sidewall.
Any crack that has a depth that is between 38 mm (1.5 inch) and 51 mm (2 inch)
is a large crack. To prepare the groove for a large crack, grind a 45 degree angle
on the sidewall.
3. If necessary, use a grinder to dress the sides and the bottom of the weld joint. The weld
must be free from carbon and rough edges. Make sure that the weld has a proper
opening.
Procedure
Table 12
Parameters for Welding Repair
Dimension (X)
Model Maximum Depth of Crack (1)
"(from flange face)"
793D
793C
793B 152.0 mm (5.98 inch) 51.0 mm (2.01 inch)
793
789C
789B
152.0 mm (5.98 inch) 38.0 mm (1.50 inch)
789
785D
785C
785B 152.0 mm (5.98 inch) 32.0 mm (1.26 inch)
785
777F
777D
777C
89.0 mm (3.50 inch) 32.0 mm (1.26 inch)
777B
777
775F
775E
775D 89.0 mm (3.50 inch) 25.0 mm (0.98 inch)
775B
773F
773E
773D 89.0 mm (3.50 inch) 25.0 mm (0.98 inch)
773B
(1)
Do not weld cracks that exceed this depth.
Welding repair is not allowed in area (A) .
Angle (B) should be 30 degrees for a crack that has a depth up to 1.5 inches. Angle (B) should be 45
degrees for a crack that has a depth from 1.5 to 2.0 inches.
Note: Be sure that the temperature of the base metal is at least 21 C (70.0 F). This
temperature must be maintained throughout the welding process. Protect the piece from
drafts. This is especially important in cold weather. This temperature is required to avoid
thermal shock. Do not confuse this temperature with the preheat temperature for the
welding area.
1. Clean the prepared weld groove with a grinder. Be sure that all slag and carbon is
removed from the weld joint.
2. Preheat the weld groove and the area that is 76 mm (3.0 inch) around the groove. The
preheat temperature is 204 C (400 F).
3. Weld the groove. Maintain an interpass temperature between 95 C (203 F) and 260
C (500 F) in the immediate weld area. For each weld pass, the fillet width must not
exceed 8 mm (0.3 inch). Use stringer welds for each weld pass.
4. After each weld pass, needle peen the weld. Make sure that all slag is removed.
5. Grind the crest of the weld to the original profile of the casting.
6. Visually inspect the weld and the surrounding area for defects.
7. After completing the repair, heat the weld area to 149 C (300 F) and allow the
casting to cool slowly to room temperature.
Welding repair may be performed on the spindles in Table 13.
Table 13
Spindles that can be Salvaged
793D
144-0518
793C
152-8887
793B
179-0744
793
793D 190-6091
789C
152-8885
789B
179-0742
789
785D
785C 152-8883
785B 179-0740
785
154-0945
785 Tractor
179-0738
154-1385
785 Wagon
179-0737
777D 119-8611
776D 152-8882
777C 107-8540
776C 152-8881
775D 106-6520
773D 179-0736
5T-2997
773B
154-1384
The spindles for the Off-Highway Truck models in Table 14 can NOT be repaired.
Table 14
Spindles that can NOT be salvaged
769 DO NOT SALVAGE
769B DO NOT SALVAGE
769C DO NOT SALVAGE
769D DO NOT SALVAGE
771C DO NOT SALVAGE
771D DO NOT SALVAGE
797 DO NOT SALVAGE
Wear limit for the Bearing Journal

Measure the diameter of the spindle at each bearing journal. Refer to Table 15, Table 16, or
Table 17 for this dimension. The acceptable tolerance for reusability of bearing journals is
"+ 0.025 mm (0.0010 inch) - 0.050 mm (0.0020 inch)".
Do not confuse this tolerance for reusability with the acceptable machining tolerance
for a spindle which has been salvaged.
Thermal Spray (Arc Spray or HVOF)

Thermal Spray can be used for the repair of bearing journal surfaces on spindles. Both Arc
Spray and HVOF are acceptable processes for this rework. Particular Arc Spray
Application for many piece parts can be found in Caterpillar Arc Spray Guideline,
SERF8473. For complete information about a Thermal Spray Application, contact Dealer
Service Operations at (309) 675-5434.
Note: Only Caterpillar dealers may utilize applications for Thermal Spray. The processes
must be carried out within the facilities of the dealership. The dealership must maintain a
clean environment. The dealership must always use the correct equipment for all processes
in each Thermal Spray Application.
Repair for Type 1 Rear Spindle Assembly

If the following areas on a Type 1 spindle show significant wear, a Thermal Spray
Application may be used in order to restore each surface to the original print size.
Bearing race diameter (A)
Bearing race diameter (B)
Seal area (C)
If you have questions concerning equipment, recommendations for powder, machine

settings, or procedures for the application, refer to Caterpillar Arc Spray Guideline,
SERF8473 or refer to the ""Thermal Spray (Arc Spray or HVOF)" " section of this
guideline. Each step in the procedure is critical to achieve the desired bond coating and the
desired finish.
Preparation of a spindle is critical to achieve the desired bond and the desired finish of the
coating.
After the Thermal Spray Application is complete, mount the spindle assembly on a lathe.
Zero the part on diameter (X) and face (Y) .
Machine the spindle to the correct dimensions. Refer to Table 15. Face (E) must be within
0.30 mm (0.0118 inch)Total Indicator Runout (TIR) of diameters (A) and (B). Diameters
(A), (B), and (C) must be within 0.08 mm (0.003 inch) TIR of each other.
The dimensions for Type 1 spindles are shown here. Refer to Table 15 for the dimensions.
Table 15
Dimensions for Type 1 Spindles

Diameter for the
Part
Model Diameters (A & Diameter (C) Length (D) Mounting
Number
B) Flange Bolt Hole
773B
27.50 + 0.50 /-
773D 247.620 0.025 474.7 0.5
5T-2378 361.85 0.05 0.25 mm (1.080 +
773E mm (9.7488 mm (18.69
mm (14.246 0.020 /- 0.010
773F 0.0010 inch) (1) 0.02 inch)
0.002 inch) inch)
773B
27.50 + 0.50 /-
773D 247.620 0.025 474.7 0.5
2G-3479 361.85 0.05 0.25 mm (1.080 +
773E mm (9.7488 mm (18.69
mm (14.246 0.020 /- 0.010
773F 0.0010 inch) (1) 0.02 inch)
0.002 inch) inch)
27.50 + 0.50 /-
247.620 0.025 474.7 0.5
2G-3479 361.85 0.05 0.25 mm (1.080 +
773 mm (9.7488 mm (18.69
mm (14.246 0.020 /- 0.010
0.0010 inch) (1) 0.02 inch)
0.002 inch) inch)
27.50 + 0.50 /-
247.620 0.025 474.7 0.5
7D-2819 361.85 0.05 0.25 mm (1.080 +
773 mm (9.7488 mm (18.69
mm (14.246 0.020 /- 0.010
0.0010 inch) (1) 0.02 inch)
0.002 inch) inch)
(1)
The tolerance for reusability is + 0.025 /- 0.050 mm (+ 0.0010 / - 0.0020 inch).
Repair for Type 2 Rear Spindle Assembly

If the following areas on a Type 2 spindle show significant wear, a Thermal Spray
Application may be used in order to restore each surface to the original print size.
Bearing race diameter (A)
Bearing race diameter (B)
If you have questions concerning equipment, recommendations for powder, machine

settings, or procedures for the application, refer to Caterpillar Arc Spray Guideline,
SERF8473 or refer to the ""Thermal Spray (Arc Spray or HVOF)" " section of this
guideline. Each step in the procedure is critical to achieve the desired bond coating and the
desired finish.
Preparation of a spindle is critical to achieve the desired bond and the desired finish of the
coating.
After the spindle has been sprayed, mount the spindle assembly on a lathe. Zero the part on
diameter (X) and face (Y). Machine the spindle to the dimensions that are shown in Table
16. Diameters (A) and (B) must be within 0.0380 mm (0.0015 inch) TIR of each other and
face (Y).
The dimensions for Type 2 spindles are shown here. Surface finish (M) is 1.6 m 63 inch. Chamfer
(P) is 15.
Refer to Table 16 for the dimensions.
Table 16
Diameter for
Part
Model Diameter (B) Length (N) Mounting
Number Diameter (A)
Flange Bolt Hole
39.00 + 0.50 /-
290 0.5
797B 247-0870 560.00 0.05 560.00 0.05 0.25 mm (1.535 +
mm (11.4
mm (22.047 mm (22.047 0.020 /- 0.010
0.02 inch)
0.002 inch) (1) 0.002 inch) inch)
247-0870 39.00 + 0.50 /-

797
560.00 0.05 560.00 0.05 290 0.5 0.25 mm (1.535 +
mm (11.4
mm (22.047 mm (22.047 0.020 /- 0.010
0.02 inch)
0.002 inch) (1) 0.002 inch) inch)
39.00 + 0.50 /-
139-7622 290 0.5
560.00 0.05 560.00 0.05 0.25 mm (1.535 +
797 247-0870 mm (11.4
mm (22.047 mm (22.047 0.020 /- 0.010
0.02 inch)
0.002 inch) (1) 0.002 inch) inch)
179-0745 33.00 + 0.50 /-

415.874 0.025 415.874 179.5 0.5
793D 152-8888 0.25 mm (1.299 +
mm (16.3730 0.025 mm mm (7.07
793F 144-0519 0.020 /- 0.010
0.0010 inch) (1) (16.3730 0.02 inch)
inch)
0.0010 inch)
33.00 + 0.50 /-
245 0.5
793D 190-6091 425.4 0.025 425.4 0.025 0.25 mm (1.299 +
mm (9.646
793F mm (16.748 mm (16.748 0.020 /- 0.010
0.020
0.0002 inch) 0.0002 inch) inch)
inch)
152-8888
144-0519 33.00 + 0.50 /-
415.874 0.025 415.874 179.5 0.5
793C 179-0745 0.25 mm (1.299 +
mm (16.3730 0.025 mm mm (7.07
139-9187 0.020 /- 0.010
0.0010 inch) (1) (16.3730 0.02 inch)
125-6605 inch)
0.0010 inch)
33.00 + 0.50 /-
415.895 0.025 415.895 179.5 0.5
793B 125-6605 0.25 mm (1.299 +
mm (16.3738 0.025 mm mm (7.07
0.020 /- 0.010
0.0010 inch) (1) (16.3738 0.02 inch)
inch)
0.0010 inch)
33.00 + 0.50 /-
415.895 0.025 415.895 179.5 0.5
793B 113-6048 0.25 mm (1.299 +
mm (16.3738 0.025 mm mm (7.07
0.020 /- 0.010
0.0010 inch) (1) (16.3738 0.02 inch)
inch)
0.0010 inch)
33.00 + 0.50 /-
415.895 0.025 415.895 179.5 0.5
793B 106-6527 0.25 mm (1.299 +
mm (16.3738 0.025 mm mm (7.07
0.020 /- 0.010
0.0010 inch) (1) (16.3738 0.02 inch)
inch)
0.0010 inch)
33.00 + 0.50 /-
415.895 0.025 415.895 179.5 0.5
793B 8X-1067 0.25 mm (1.299 +
mm (16.3738 0.025 mm mm (7.07
0.020 /- 0.010
0.0010 inch) (1) (16.3738 0.02 inch)
inch)
0.0010 inch)
33.00 + 0.50 /-
415.895 0.025 415.895 179.5 0.5
8X-1067 0.25 mm (1.299 +
793 mm (16.3738 0.025 mm mm (7.07
0.020 /- 0.010
0.0010 inch) (1) (16.3738 0.02 inch)
inch)
0.0010 inch)
34.00 + 0.50 /-
380.970 0.025 384.145 173.0 0.5
789C 179-0743 0.25 mm (1.339 +
mm (14.9988 0.025 mm mm (6.81
0.020 /- 0.010
0.0010 inch) (1) (15.1238 0.02 inch)
inch)
0.0010 inch)
34.00 + 0.50 /-
380.970 0.025 384.145 173.0 0.5
789C 152-8886 0.25 mm (1.339 +
mm (14.9988 0.025 mm mm (6.81
0.020 /- 0.010
0.0010 inch) (1) (15.1238 0.02 inch)
inch)
0.0010 inch)
34.00 + 0.50 /-
380.970 0.025 384.145 173.0 0.5
789B 152-8886 0.25 mm (1.339 +
mm (14.9988 0.025 mm mm (6.81
0.020 /- 0.010
0.0010 inch) (1) (15.1238 0.02 inch)
inch)
0.0010 inch)
34.00 + 0.50 /-
380.970 0.025 384.145 173.0 0.5
789B 129-1526 0.25 mm (1.339 +
mm (14.9988 0.025 mm mm (6.81
0.020 /- 0.010
0.0010 inch) (1) (15.1238 0.02 inch)
inch)
0.0010 inch)
34.00 + 0.50 /-
380.970 0.025 384.145 173.0 0.5
789B 8X-8093 0.25 mm (1.339 +
mm (14.9988 0.025 mm mm (6.81
0.020 /- 0.010
0.0010 inch) (1) (15.1238 0.02 inch)
inch)
0.0010 inch)
34.00 + 0.50 /-
380.970 0.025 384.145 173.0 0.5
8X-8093 0.25 mm (1.339 +
789 mm (14.9988 0.025 mm mm (6.81
0.020 /- 0.010
0.0010 inch) (1) (15.1238 0.02 inch)
inch)
0.0010 inch)
34.00 + 0.50 /-
380.970 0.025 384.145 173.0 0.5
5T-5748 0.25 mm (1.339 +
789 mm (14.9988 0.025 mm mm (6.81
0.020 /- 0.010
0.0010 inch) (1) (15.1238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
785D 317.457 0.025 346.032 170.0 0.5
152-8884 0.25 mm (1.083 +
785C mm (12.4983 0.025 mm mm (6.69
0.020 /- 0.010
0.0010 inch) (1) (13.6233 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
317.457 0.025 346.032 170.0 0.5
785B 152-8884 0.25 mm (1.083 +
mm (12.4983 0.025 mm mm (6.69
0.020 /- 0.010
0.0010 inch) (1) (13.6233 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
785D 317.457 0.025 346.032 170.0 0.5
131-2524 0.25 mm (1.083 +
785B mm (12.4983 0.025 mm mm (6.69
0.020 /- 0.010
0.0010 inch) (1) (13.6233 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
317.457 0.025 346.032 170.0 0.5
131-2524 0.25 mm (1.083 +
785 mm (12.4983 0.025 mm mm (6.69
0.020 /- 0.010
0.0010 inch) (1) (13.6233 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
317.457 0.025 346.032 170.0 0.5
6G-6574 0.25 mm (1.083 +
785 mm (12.4983 0.025 mm mm (6.69
0.020 /- 0.010
0.0010 inch) (1) (13.6233 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 288.895 116.9 0.5
777D 152-8882 0.25 mm (1.083 +
mm (9.2488 0.025 mm mm (4.60
0.020 /- 0.010
0.0010 inch) (1) (11.3738 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 269.845 122.2 0.5
777C 107-8540 0.25 mm (1.083 +
mm (9.2488 0.025 mm mm (4.81
0.020 /- 0.010
0.0010 inch) (1) (10.6238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 269.845 122.2 0.5
777C 7I-5633 0.25 mm (1.083 +
mm (9.2488 0.025 mm mm (4.81
0.020 /- 0.010
0.0010 inch) (1) (10.6238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 269.845 122.2 0.5
777B 7I-5633 0.25 mm (1.083 +
mm (9.2488 0.025 mm mm (4.81
0.020 /- 0.010
0.0010 inch) (1) (10.6238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 269.845 122.2 0.5
777B 5T-3083 0.25 mm (1.083 +
mm (9.2488 0.025 mm mm (4.81
0.020 /- 0.010
0.0010 inch) (1) (10.6238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 269.845 122.2 0.5
5T-3083 0.25 mm (1.083 +
777 mm (9.2488 0.025 mm mm (4.81
0.020 /- 0.010
0.0010 inch) (1) (10.6238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 269.845 122.2 0.5
9D-9252 0.25 mm (1.083 +
777 mm (9.2488 0.025 mm mm (4.81
0.020 /- 0.010
0.0010 inch) (1) (10.6238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
234.920 0.025 269.845 122.2 0.5
8X-9081 0.25 mm (1.083 +
777 mm (9.2488 0.025 mm mm (4.81
0.020 /- 0.010
0.0010 inch) (1) (10.6238 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
775D 247.620 0.025 247.620 119.5 0.5
106-6520 0.25 mm (1.083 +
775E mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
775F 0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
775B 106-6520 0.25 mm (1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
775B 7I-5445 0.25 mm (1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
775B 8W-7079 0.25 mm (1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
773D 247.620 0.025 247.620 119.5 0.5
106-6520 0.25 mm (1.083 +
773E mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
773F 0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
773B 106-6520 0.25 mm (1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
773B 7I-5445 0.25 mm (1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
773B 106-6520 0.25 mm (1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
773B 8W-7079 0.25 mm (1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch)
0.0010 inch)
27.50 + 0.50 /-
247.620 0.025 247.620 119.5 0.5
773B 5T-2997 0.25 mm 1.083 +
mm (9.7488 0.025 mm mm (4.70
0.020 /- 0.010
0.0010 inch) (1) (9.7488 0.02 inch)
inch
0.0010 inch)
17.00 + 0.40 /-
203.170 0.025 209.520 91.9 0.5
771D 5T-2993 0.15 mm 0.669 +
mm (7.9988 0.025 mm mm (3.62
0.016 /- 0.006
0.0010 inch) (1) (8.2488 0.02 inch)
inch
0.0010 inch)
17.00 + 0.40 /-
203.170 0.025 209.520 91.9 0.5
771C 5T-2993 0.15 mm (0.669 +
mm (7.9988 0.025 mm mm (3.62
0.016 /- 0.006
0.0010 inch) (1) (8.2488 0.02 inch)
inch)
0.0010 inch)
17.00 + 0.40 /-
203.170 0.025 209.520 91.9 0.5
769D 5T-2993 0.15 mm (0.669 +
mm (7.9988 0.025 mm mm (3.62
0.016 /- 0.006
0.0010 inch) (1) (8.2488 0.02 inch)
inch)
0.0010 inch)
17.00 + 0.40 /-
203.170 0.025 209.520 91.9 0.5
769C 5T-2993 0.15 mm (0.669 +
mm (7.9988 0.025 mm mm (3.62
0.016 /- 0.006
0.0010 inch) (1) (8.2488 0.02 inch)
inch)
0.0010 inch)
17.48 + 0.40 /-
203.170 0.025 209.520 91.9 0.5
769C 2G-5549 0.15 mm (0.688 +
mm (7.9988 0.025 mm mm (3.62
0.016 /- 0.006
0.0010 inch) (1) (8.2488 0.02 inch)
inch)
0.0010 inch)
13.49 + 0.40 /-
203.170 0.025 209.520 91.9 0.5
769B 5D-6357 0.15 mm (0.531 +
mm (7.9988 0.025 mm mm (3.62
0.016 /- 0.006
0.0010 inch) (1) (8.2488 0.02 inch)
inch)
0.0010 inch)
13.49 + 0.40 /-
203.170 0.025 209.520 91.9 0.5
5D-6357 0.15 mm (0.531 +
769 mm (7.9988 0.025 mm mm (3.62
0.016 /- 0.006
0.0010 inch) (1) (8.2488 0.02 inch)
inch
0.0010 inch)
13.49 + 0.40 /-
203.182 0.025 204.770 96.0 0.5
769 5D-1142 0.15 mm (0.531 +
mm (7.9993 0.025 mm mm (3.78
(RH) 0.016 inch /-
0.0010 inch) (1) (8.0618 0.02 inch)
0.006)
0.0010 inch)
13.49 + 0.40 /-
203.182 0.025 204.770 96.0 0.5
769 5D-1142 0.15 mm (0.531 +
mm (7.9993 0.025 mm mm (3.78
(LH) 0.016 inch /-
0.0010 inch) (1) (8.0618 0.02 inch)
0.006)
0.0010 inch)
(1)
The tolerance for reusability is + 0.025 /- 0.050 mm (+ 0.0010 / - 0.0020 inch).
Repair for Type 3 Front Spindle Assembly

If diameter (A) and diameter (B) are worn, a Thermal Spray operation may be used to
restore the diameter of the bearing race to the original dimension. If you have questions
concerning equipment, recommendations for powder, machine settings, or procedures for
the application, refer to Caterpillar Arc Spray Guideline, SERF8473 or refer to the
""Thermal Spray (Arc Spray or HVOF)" " section of this guideline. Each step in the
procedure is critical to achieve the desired bond coating and the desired finish. Preparation
of the spindle is critical to achieve the desired bond and the desired finish of the coating.
After the spindle has been sprayed, mount the spindle assembly on a lathe. Zero the part on
diameter (X) and face (Y). Machine the spindle to the dimensions that are shown in Table
17. Diameter (A) and diameter (B) must be within 0.038 mm (0.0015 inch). Both diameters
must be within the maximum total indicator reading of each other and face (Y).
The dimensions for Type 3 spindles are shown here. The surface finish (M) is 1.6 m (63 inch).
Chamfer (P) is 15. Refer to Table 17 for the dimensions.
Table 17
Part
Model Assembly
Number Diameters (A) Diameter (B) Length (T)
797B 144-0804 152-1671 346.032 0.025 415.874 0.025

166.12 mm
mm (13.6233 mm (16.3730
(6.540 inch)
0.0010 inch) (1) 0.0010 inch)
144-0804 152-1671 346.032 0.025 415.874 0.025

797 166.12 mm
mm (13.6233 mm (16.3730
(6.540 inch)
0.0010 inch) (1) 0.0010 inch)
793C
793D 8X-1468 174-7531 231.745 0.025 317.470 0.025
130.26 mm
793F mm (9.1238 mm (12.4988
(5.128 inch)
0.0010 inch) (1) 0.0010 inch)
793D 247-0895 244-7765 260.3 0.025 mm 330 2 mm

(10.24801 (12.99210 160 0.5 mm
0.00098 inch) 0.07874 inch) (6.29920
0.01969 inch)
174-7531
793C 8X-1468 231.745 0.025 317.470 0.025
8X-8410 130.26 mm
mm (9.1238 mm (12.4988
(5.128 inch)
0.0010 inch) (1) 0.0010 inch)
8X-8410
793B 8X-1468 231.745 0.025 317.470 0.025
174-7531 130.26 mm
mm (9.1238 mm (12.4988
(5.128 inch)
0.0010 inch) (1) 0.0010 inch)
8X-8410
8X-1468 231.745 0.025 317.470 0.025
793 174-7531 130.26 mm
mm (9.1238 mm (12.4988
(5.128 inch)
0.0010 inch) (1) 0.0010 inch)
789C 183-7419 5T-1023 231.745 0.025 269.845 0.025

117.76 mm
mm (9.1238 mm (10.6238
(4.636 inch)
0.0010 inch) (1) 0.0010 inch)
789C 8X-9561 5T-1023 231.745 0.025 269.845 0.025

117.76 mm
mm (9.1238 mm (10.6238
(4.636 inch)
0.0010 inch) (1) 0.0010 inch)
789B 8X-9561 5T-1023 231.745 0.025 269.845 0.025

117.76 mm
mm (9.1238 mm (10.6238
(4.636 inch)
0.0010 inch) (1) 0.0010 inch)
8X-9561 5T-1023 231.745 0.025 269.845 0.025

789 117.76 mm
mm (9.1238 mm (10.6238
(4.636 inch)
0.0010 inch) (1) 0.0010 inch)
5T-6116 5T-1023 231.745 0.025 269.845 0.025

789 117.76 mm
mm (9.1238 mm (10.6238
(4.636 inch)
0.0010 inch) (1) 0.0010 inch)
785 D 183-7418 309-9597 231.745 0.025 269.845 0.025

117.76 mm
mm (9.1238 mm (10.6238
(4.636 inch)
0.0010 inch) (1) 0.0010 inch)
785C 183-7418 6G-9270 231.745 0.025 269.845 0.025

113.00 mm
mm (9.1238 mm (10.6238
(4.449 inch)
0.0010 inch) (1) 0.0010 inch)
8X-8950
785C 6G-9270 231.745 0.025 269.845 0.025
183-7418 113.00 mm
mm (9.1238 mm (10.6238
(4.449 inch)
0.0010 inch) (1) 0.0010 inch)
8X-8950
785B 6G-9270 231.745 0.025 269.845 0.025
183-7418 113.00 mm
mm (9.1238 mm (10.6238
(4.449 inch)
0.0010 inch) (1) 0.0010 inch)
8W-5599
785B 8X-8950 6G-9270 231.745 0.025 269.845 0.025
113.00 mm
183-7418 mm (9.1238 mm (10.6238
(4.449 inch)
0.0010 inch) (1) 0.0010 inch)
8W-5599
8X-8950 6G-9270 231.745 0.025 269.845 0.025
785 113.00 mm
183-7418 mm (9.1238 mm (10.6238
(4.449 inch)
0.0010 inch) (1) 0.0010 inch)
5T-6063
8W-5599
6G-9270 231.745 0.025 269.845 0.025
785 8X-8950 113.00 mm
mm (9.1238 mm (10.6238
183-7418 (4.449 inch)
0.0010 inch) (1) 0.0010 inch)
243-5532
777F 183-7417 243-5549 231.745 0.025
261-2356 mm (9.1238
0.0010 inch)
777D 183-7417 6G-9270 152.370 0.025 199.944 0.025

130.00 mm
mm (5.9988 mm (7.8718
(5.118 inch)
0.0010 inch) (1) 0.0010 inch)
5T-2098
777D 6G-9270 152.370 0.025 199.944 0.025
183-7417 130.00 mm
mm (5.9988 mm (7.8718
(5.118 inch)
0.0010 inch) (1) 0.0010 inch)
5T-2098
777C 6G-9270 152.370 0.025 199.944 0.025
183-7417 130.00 mm
mm (5.9988 mm (7.8718
(5.118 inch)
0.0010 inch) (1) 0.0010 inch)
5T-2098
777B 6G-9270 152.370 0.025 199.944 0.025
183-7417 130.00 mm
mm (5.9988 mm (7.8718
(5.118 inch)
0.0010 inch) (1) 0.0010 inch)
5T-2098
6G-9270
777 183-7417 130.00 mm
152.370 0.025 199.944 0.025 (5.118 inch)
mm (5.9988 mm (7.8718
0.0010 inch) (1) 0.0010 inch)
9D-1388 9D-2750 152.370 0.025 199.944 0.025

777 130.00 mm
mm (5.9988 mm (7.8718
(5.118 inch)
0.0010 inch) (1) 0.0010 inch)
775D 133-4727 6G-8241 133.320 0.025 152.370 0.025

128.50 mm
mm (5.2488 mm (5.9988
(5.059 inch)
0.0010 inch) (1) 0.0010 inch)
6G-6440
775D 6G-8241 133.320 0.025 152.370 0.025
133-4727 128.50 mm
mm (5.2488 mm (5.9988
(5.059 inch)
0.0010 inch) (1) 0.0010 inch)
6G-6440
775B 6G-8241 133.320 0.025 152.370 0.025
133-4727 128.50 mm
mm (5.2488 mm (5.9988
(5.059 inch)
0.0010 inch) (1) 0.0010 inch)
773D 133-4727 6G-8241 133.320 0.025 152.370 0.025

128.50 mm
mm (5.2488 mm (5.9988
(5.059 inch)
0.0010 inch) (1) 0.0010 inch)
6G-6440
773D 6G-8241 133.320 0.025 152.370 0.025
133-4727 128.50 mm
mm (5.2488 mm (5.9988
(5.059 inch)
0.0010 inch) (1) 0.0010 inch)
6G-6440
773B 6G-8241 133.320 0.025 152.370 0.025
133-4727 128.50 mm
mm (5.2488 mm (5.9988
(5.059 inch)
0.0010 inch) (1) 0.0010 inch)
7D-2891
773B 7D-2834 133.320 0.025 152.370 0.025
7D-2820 128.50 mm
mm (5.2488 mm (5.9988
(5.059 inch)
0.0010 inch) (1) 0.0010 inch)
771D 6G-6430 6G-8240 120.620 0.025 139.670 0.025

109.50 mm
mm (4.7488 mm (5.4988
(4.311 inch)
0.0010 inch) (1) 0.0010 inch)
771C 6G-6430 6G-8240 120.620 0.025 139.670 0.025

109.50 mm
mm (4.7488 mm (5.4988
(4.311 inch)
0.0010 inch) (1) 0.0010 inch)
769D 6G-6430 6G-8240 120.620 0.025 139.670 0.025

109.50 mm
mm (4.7488 mm (5.4988
(4.311 inch)
0.0010 inch) (1) 0.0010 inch)
769C 6G-6430 6G-8240 120.620 0.025 139.670 0.025

109.50 mm
mm (4.7488 mm (5.4988
(4.311 inch)
0.0010 inch) (1) 0.0010 inch)
769C 6D-0093 2G-2100 120.620 0.025 139.670 0.0254

109.50 mm
mm (4.7488 mm (5.4988
(4.311 inch)
0.0010 inch) (1) 0.0010 inch)
769B 6D-0093 2G-2100 120.620 0.025 139.670 0.0254

109.50 mm
mm (4.7488 mm (5.4988
(4.311 inch)
0.0010 inch) (1) 0.0010 inch)
5D-8203 77.770 0.13 mm 129.982 0.13

769 N/A 155.58 mm
(3.062 0.005 mm (5.1174
(6.125 inch)
inch) 0.005 inch)
9M-1683 77.770 0.13 mm 129.982 0.13

769 N/A 150.42 mm
(3.062 0.005 mm (5.1174
(5.922 inch)
inch) 0.005 inch)
(1)
The tolerance for reusability is + 0.025 /- 0.050 mm (+ 0.0010 /- 0.0020 inch).
2 "11, 0!!0 2 % 3 6 8 "000 !" /. 9! !!0!!0

$ 4 4 5 3
5 & 6%67 4 43

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By NPR - SEBF8083 - Inspection and Salvage of Wheel Spi...

Inspection and Salvage of Wheel Spindles for all Off-

Off-Highway Truck/Tractor: All

Caterpillar Dealer Technical Communicator

Dealer Solution Network

Caterpillar Technical Representative

Important Safety Information

This safety alert symbol means:

Your Safety is Involved.

Caterpillar cannot anticipate every possible circumstance that might involve a

Personal injury or death can result from lifting a

The heavy assembly can fall if using an incorrect hoist

Be sure the hoist has the correct capacity to lift a

The approximate weight of 247-0870 Spindle Assembly is 3647 kg (8040 lb).

SERF8473 "Arc Spray Guide- CD-Rom"

Checklist for Inspection and Salvage of Wheel Spindles

Protective Equipment, Tools and Materials Needed

Inspection Application Comments

Rotary wire Cleaning all mounting

Adequate Machining and inspection of

Identification of Spindle Type

Typical front spindle

Typical front spindle

Typical rear spindle

Identification of Areas that Wear

Wheel Bearing Journals

This is an inner journal that exhibits normal wear.

In order to recondition the surface of a bearing journal, refer to CD-ROM, SERF8705,

Refer to Tables 15, 16, or 17.

DO NOT USE AGAIN

This outer journal exhibits scratching and spalling damage.

DO NOT USE AGAIN

This is an outer journal that exhibits heavy damage from spalling.

DO NOT USE AGAIN

DO NOT USE AGAIN

This is an inner journal that exhibits scratching and spalling damage.

DO NOT USE AGAIN

DO NOT USE AGAIN

Brake Anchor Flange

DO NOT USE AGAIN

This illustration shows a different view of the crack.

DO NOT USE AGAIN

(AA) AETA hole

(BB) Lubrication hole

(AA) AETA hole

(BB) Lubrication hole

(1) Lubrication hole

(2) Neutral axis

(3) Angle (45 degrees)

(X) Length (Table 6)

(1) Lubrication hole

(X) Length (Table 6)

No visible defects are allowed.

(1) Lubrication hole

No more than 15 total indications are allowed in this region.

(1) Lubrication hole

(X) Length (Table 6)

(1) Lubrication hole

(X) Length (Table 6)

(1) Lubrication hole

No more than 10 total indications are allowed in this region.

(1) Lubrication hole

No more than 10 total indications are allowed in this region.

Example of porous indications