Guia de Reusabilidad de Engranajes

2021/03/09 Reuse and Salvage for Gear Train and Gear Shafts on Engines {0679, 1151, 1162, 1206}
, 1162, 1206} (SEBF9244)
SMCS - 0679,1151,1162,1206 i08377592

Caterpillar Products
All Cat Engines
Revision History:
Revision Summary of Changes in SEBF9244
Added 430-8140 to Table 6 and 478-5468 and 478-5469 to Table 32.
14 Reworked Table 21 for clarity on options.
Added new serial number prefixes.
13 Added new serial number prefixes.
Table 8, 10, and 12 a service replacement part was released.
12
Added New serial number prefixes.
11 Added note to Table 32 indicating 131-7123 is a service replacement for 128-2661.
10 Added New serial number prefixes.
08–09 Corrected callouts.- Added C175 aux and PTO shafts.
Combined information from M0068228, SEBF8045, SEBF8188, SEBF8377, SEBF9191, SEBF9192,
07
SEBF9316, added 29 part numbers and repaired 14 pixelated illustrations.
Table 1
Introduction
© 2021 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document
or the proprietary processes therein without permission may be violation of intellectual property law.
Information contained in this document is considered Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability
program. Reuse and salvage information enables Cat 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.
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, procedure, work method, or operating
technique not recommended by Caterpillar is used, ensure that the procedure is safe everyone. Ensure that the product will
not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures 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.
The "WARNING" safety alert symbol is shown below.
https://sis2.cat.com/#/detail?keyword=SEBF8045&tab=3&serialNumber=&infoType=43&serviceMediaNumber=SEBF9244&serviceIeSystemControlNumber=i05146489
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
The illustrations in this guideline show specific examples of reusability for gears and gear shafts for engines. Normally, the
reusability of the gears is determined from the condition of the gear teeth. Damage in other areas on the gear is not common
and easily identified.
If a gear is within specifications, the gear can be expected to give normal performance until the next overhaul when used
again in the same application. Correct all conditions that damaged the gear.
Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about
canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Service Letters and Technical Information Bulletins
NOTICE
The most recent Service Letters and Technical Information
Bulletins that are related to this component shall be reviewed
before beginning work. Often Service Letters and Technical
Information Bulletins contain upgrades in repair procedures,
parts, and safety information that pertain to the parts or
components being repaired.
References
References
Media Number Title

SEBF8187 Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".
SEBF9066 Applied Failure Analysis, "Guideline for Examining Failed Parts".
SEHS9826 Special Instruction, "Ordering "Series B" Replacement Cylinder Blocks for 3500 Series Engines"
Table 2
Tooling and Equipment
NOTICE
Failure to follow the recommended procedure or the specified
tooling that is required for the procedure could result in damage
to components.
To avoid component damage, follow the recommended

procedure using the recommended tools.
Required Tooling and Equipment
Part Number Description

1P-3048 Wrench Assembly
1P-3537 Dial Bore Gauge Kit
3P-1568 Dial Indicator
4C-9442 Flashlight
4C-9991 Tool Group
5P-4160 Tip
5P-4456 Base
5P-6518 Dial Indicator Fixture
6V-2010 Polishing Stone
6V-7059 Micrometer
8S-2257 Eye Loupe
8T-5096 Dial Indicator Group
9A-1593 Surface Texture Comparison Gauge
222-3062 Air Drill
Pocket Microscope
262-8390
40X
303-9339 Lint Free Shop Towels
Micrometer Extensions,
Internal
385-9422
50 - 609 mm
(2 - 24 inch)
Digital Caliper
423-4373 0.0 - 203.2 mm
(0.00 - 8.00 inch)
Micrometer, External
431-4150
25 mm (1 inch)
448-3698 Profilometer
Micrometer, Inside
473-8688 2.00 - 12.00 inch
or
473-8689 Micrometer, Inside
50 - 300 mm
Micrometer, Outside
473-8690
0.00 - 4.00 inch
Outside Electronic Micrometer Set
473-8691
2-6 inch
Micrometer, Outside
473-8692
152.4 - 304.8 mm (6.00 - 12.00 inch)
Micrometer, Inside
474-3709 (8.00 - 32.00 inch)
or
474-3710 Micrometer, Inside
200 - 800 mm
549-3500 Precision Gage Pin Set
Precision Gage Pins
549-3505 4.000 mm
(0.15748 inch)
Precision Gage Pins
549-3506 5.000 mm
(0.19685 inch)
Precision Gage Pins
549-3508 6.000 mm
(0.23622 inch)
Precision Gage Pins
549-3510 8.000 mm
(0.31496 inch)
Precision Gage Pins
549-3512 10.000 mm
(0.39370 inch)
FT3302 TIR Tooling
- Carbide tipped drill bit 5.94 mm (0.234 inch)
- Cobalt drill bit 5.94 mm (0.2339 inch)
Precision Gage Pins
- 4.7625 mm
(0.18750 inch)
Precision Gage Pins
- 6.350 mm
(0.25000 inch)
Table 3
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. Use a metal marking pen to mark the code onto the component.
NOTICE
Do not use numbering stamp punches to mark internal
components. The impact from striking the stamp will cause an
abnormal stress riser. The added stress riser may cause
premature part failure.
DO NOT use numbering stamp punches to mark internal components.
The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different
territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.
Example 1
Typical Example
Illustration 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
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.
Measurement Requirements
NOTICE
Precise measurements shall be made when the
component and measurement equipment are at 20°
(68° F). Measurements shall be made after both the
component and measurement equipment have had
sufficient time to soak at 20° (68° F). This will ensure
that both the surface and core of the material is at the
same temperature.
Prepare the Area for Inspection

Reference: , SEBF9066Applied Failure Analysis, "Guideline for Examining Failed Parts".
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.
The first step of visual examination is to prepare the surface of the part for inspection. Even thin layers of oil, grease, or
other materials may hide important facts. Aggressive cleaning methods employing harsh chemicals, glass beads, soda
blasting, or hand scrubbing should be avoided as these methods can remove facts that aid in determining the type and
location of additional testing that may be needed. Soft brushes and mild solvents usually work best for cleaning parts.
These cleaning methods should be avoided on parts. Surface damage during cleaning is likely.
To summarize cleaning requirements for parts, remember that the objective is to not further damage or wear areas before
the areas can be inspected. Keep in mind these things when cleaning parts:
Remove all removable plugs before cleaning.
Use appropriate thread taps to chase all threaded holes.
Use a fast drying, mild solvent to soak and/or rinse parts clean.
Make sure that you remove all debris, paint, and oil but Do Not wipe, scrub, or scratch to clean part.
When you move parts that require cleaning, always use a proper lifting device. This device must protect the
part from damage. For the safety of the operator, all lifting devices must be inspected before use.
Do not wipe parts with a shop towel to dry, air dry, blow with dry compressed air, or blot dry with a paper
towel.
Polishing
Note: Do not use polishing stone on shaft journals.
6V-2010 Polishing Stone and oil should be used to polish a tooth. Be aware of the adjacent tooth. The corner of the stone can easily damage adjacent
teeth.
A grinder had been used on this gear in an attempt to recondition the teeth. Use 6V-2010 Polishing Stone and oil for reconditioning the teeth on a gear.
Do not use a grinder. The grinding process can remove the case hardened surface of a gear.
DO NOT USE THIS PART AGAIN.
Gears with limited damage on the surface may be used again after the damaged area has been polished with 6V-2010
Polishing Stone and oil. Caterpillar recommends the use of a polishing stone and oil. Never use a die grinder to recondition
a gear. Refer to Illustration 8.
NOTICE
If the tooth has a raised metal area, remove only the raised
portion. Do not try to remove pitting or any other recessed
surface damage. Do not use a grinder or power polisher, use
only a hand-held stone. Using power tools to remove damage
can also remove the case hardened surface of the gear, causing
eventual failure.
Nomenclature for Front and Rear Gear Train

3500 Front Gear Train
(1) High-Speed Idler Gear or Low Speed Idler Gear
(2) Bearing Sleeve for Adapter Assembly
(3) Bearing Sleeve
(4) Accessory Drive Gear
3500 Rear Gear Train
(1) Ring
(2) Camshaft Drive Gear
(3) Idler Gear Assembly
(4) Bearing Sleeve
(5) Thrust Washer
(6) Bolt
(7) Cluster Gear Shaft
(8) Idler Gear Shaft
(9) Bolt
(10) Bolt
(11) Bearing Sleeve
(12) Bolt
(13) Hard Washer
(14) Cluster Gear Assembly
(15) Thrust Plate
(16) Plate
(17) Bolt
(18) Bolt
(19) Crankshaft Gear
C175 Front Gear Train
(1) Fuel Pump Adapter
(2) Oil Pump Adapter
(3) Bearing Sleeve
(4) Low Speed Idler Gear, Medium Speed Idler Gear, or High-Speed Idler Gear
(5) Crankshaft Gear
(6) Low, Medium, or High-Speed Accessory Drive Gear
(7) Pump Drive Shaft
(8) Bearing Sleeve
(9) Front Adapter
(10) Idler Shaft
Accessory Drive Gear (6) and Idler Gear (4).
(A) High-Speed Drive Gear
(B) Medium Speed Drive Gear
(C) Low Speed Drive Gear
TheC175 Engines use either a low, medium, or high-speed accessory drive. The HIGH speed models use a 53 Tooth Idler
Gear (5) and a 61 Tooth Accessory Drive Gear (7). The MEDIUM speed models use a 57 Tooth Idler Gear (5) and a 53 tooth
Accessory Drive Gear (7). The LOW speed models use a 64 Tooth Idler Gear (5) and a 41 tooth Accessory Drive Gear (7).
Make sure to check your gears to be sure that the correct dimensions are used.
C175 Rear Gear Train
(1) Camshaft
(2) Camshaft Gear
(3) Cluster Gear Shaft
(4) Idler Gear
(5) Bearing Sleeve
(6) Crankshaft Gear
Visual Inspection of Gears

Glossary
Excessive - Exceeding acceptable amounts
Machining - Finish a surface with a machine.
Pitting - Small holes from corrosion and wear
Polished - Surface that is smooth and shiny as a result of wear
Nomenclature of Gear Tooth

Positive identification of the type of damage on a gear is important. Remember to check all the gear teeth.
Use the following tools to identify damaged areas during the inspection process:
Magnifying glass
Strong light source
White paper
(1) End
(2) Tip
(3) Edge
(4) Face of the Tooth
(5) Pitch line
(6) Radius
(7) Profile
Teeth on a new gear
Effects of Wear
The polished areas are examples of normal wear.
Use the gear again.
The gears that are shown in Illustration 16 and Illustration 17 show some loss of material from the teeth in addition to areas
that are polished.
Use the gear again.
The areas indicate a typical area of normal wear.
Use the gear again.
Do not use the gear again if either side of the worn area can be felt with a fingernail.
The areas of wear show some light corrosion.
Use the gear again.
Oil can cause discoloration on sections of some teeth.
Use the gear again.
The surfaces of the gear teeth are not polished. Not polished gear teeth surfaces are an indication of excessive wear. Also
see Illustration 22.
Do not use the gear again.
The faces of the gear teeth are not polished. Not polished gear teeth faces are an indication of excessive wear.
Excessive wear has destroyed the profiles of the teeth.
The amount of wear is different on each tooth.
Effects of Pitting
Pitting on the ends of the teeth
Use the gear again.
Pitting at the pitch line of each tooth
Pitting in the radius of each gear tooth
Examples of heavy pitting
Examples of heavy pitting and excessive wear
Light pitting that has been polished.
Use the gear again.
Effects of Machining
The gear teeth contain marks from machining and some light pitting.
Use the gear again.
NOTICE
Know the difference between the type of lips shown here and
lips that result from severe plastic yielding. Refer to the "Severe
Plastic Yielding" section of this guideline.
Machining can sometimes cause lips on both edges of the gear tooth.
Use the gear again.
Use the gear again only if the lips are of even height.
Typical marks from machining
Use the gear again.
Note: Illustration 37 is not a gear. However, these marks appear similar on all gears.
Typical horizontal and vertical machining marks
Use the gear again.
Nicks, Cracks, and Other Damage to the Surface
Small nicks on one edge and the tip of a tooth
Use the gear again.
Use the gear again after the sharp edges of the nick are smoothed with a 6V-2010 Polishing Stone.
A small nick on the face of the tooth
Use the gear again.
Use the gear again after the sharp edges of the nick are smoothed with a 6V-2010 Polishing Stone.
A nick on the end of a tooth
Use the gear again.
Use the gear again after the sharp edges in the immediate area of the face of the tooth are smoothed with a 6V-2010
Polishing Stone.
A crack in the end of a tooth
A deep gouge across the center of the tooth face.
Raised ridges along the faces of the teeth
Severe Plastic Yielding

Severe plastic yielding is caused by a heavy flow of surface material. Severe plastic yielding results in the development of
lips on the ends, edges, and/or tips of the gear teeth. Severe plastic yielding causes uneven lips, whereas lips from
machining are even. Refer to Illustration 36 for machining lips.
This gear is a typical example of severe plastic yielding. The lips are not of even height.
This gear contains severe plastic yielding. The lips are not of even height.
Scoring
Vertical lines on the face of the tooth are indications of scoring.
Use the gear again.
Note: Scoring is not a common problem in gears.
Fuel Pump Gear Inspection

1. Perform gear inspection, if the gear passes visual inspection of the gear continue to checking end play. If the gear
does not pass inspection, replace the gear.
2. With the gear standing upright on a table, hold the outer gear tightly while trying to rotate the inner hub. Look and feel
for movement between the two pieces. Movement may feel like clicking or knocking. There should be no movement
between the hub and outer gear. If there is movement between the hub and gear replace the gear.
3. Fasten tooling FT3302 with two bolts and nuts.
4. Place the plate from tooling FT3302 on a suitable work surface. Secure the plate to the work surface. The clamps used
to secure the plate must be outside the radius of the pins.
5. Place the dial indicator into a hole next to tooling FT3302. Zero dial indicator.
6. Attach torque wrench to tooling FT3302. Apply 35 N·m (26 lb ft). Observe TIR reading and record when 35 N·m
(26 lb ft) is reached. The limit for reuse is 0.045 mm (0.0018 inch) at 35 N·m (26 lb ft). If the gear does not meet the
TIR specification, the gear should be replaced. The gear is not serviceable.
Wear Limit for Bronze Thrust Washers

Hub Motion Relative to the Gear
Radial Axial
New 0.06 - 0.12 mm (0.00236 - 0.00472 inch) 0.19 - 0.31 mm (0.00748 - 0.01220 inch)
Maximum Wear 0.15 mm (0.00591 inch) 0.037 mm (0.00146 inch)
Table 4
Visual Inspection of Gear Shafts

Note: Ensure that all removable plugs are removed before visual inspection, if plugs are not removed, remove and
perform the cleaning process.
Critical Areas on Gear Shafts

The surfaces at location (A) & (B) are critical to the performance of the shaft and must conform to the reuse
specifications for surface texture and diameter. Reconditioning of these surfaces is not recommended. Check
location (C), for wear steps and make sure that the Oil Holes (D) are free of debris by flushing the holes with oil.
Visual reference example of C175 and 3500 auxiliary shafts
Visual reference example of C175 oil & water pump shafts
Visual reference example of C175 idler shafts
Visual reference example of 3500 PTO shafts
Visual reference example of C175 PTO shafts
Check the splines of the gear shaft for wear steps.
Examples of Acceptable Wear on Gear Shafts

Nicks and Dings
Most nicks and dings are acceptable as long as the shaft meets minimum surface texture and other reuse specifications.
Use Again if Shaft Meets Minimum Specifications.
Scratches and Light Rust

Gear shafts with scratches and light rust can be reused as long as the shaft meets minimum specifications after cleaning
with non-abrasive methods.
Other Acceptable Damage Types
Minor damage on the wear sleeve surface. Use Again if Shaft Meets Minimum Specifications.
Rough surface on a non-critical area of Idler Shaft. Use Again if Shaft Meets Minimum Specifications.
Examples of Unacceptable Wear on Gear Shafts

Gear shafts can be reused as long as the shaft meets the minimum specifications in the critical areas shown in Illustration
56 - 60. Shafts with small nicks are acceptable, and the shaft must meet minimum specifications and there are no raised
material surrounding the nick.
This shaft has excessive amounts of corrosion in a critical area (A) and cannot be reused. Do Not Use Again.
This shaft has excessive amounts of corrosion in a critical area (B) and cannot be reused. Do Not Use Again.
There are heavy scratches and corrosion and significant raised material on the gear shaft. Do Not Use Again.
Specifications for Auxiliary, Oil & Water Pump Shafts
Auxiliary, Oil & Water Pump Shaft Diameters and Surface Textures
Surface Texture of Minimum Length (C) Surface Texture
Part Diameter of Shorter Diameter of Longer
Shorter End of for Surface Texture of Longer End
Number End of Shaft (A) End of Shaft (D)
Shaft (B) of (E) of Shaft (E)
Ø 74.9 ± 0.015 mm
246-6691
(2.949 ± 0.0006 inch)
0.80 µm Ø 93.9 ± 0.015 mm 0.80 µm
251-5516 Ø 74.9 ± 0.015 mm
(31.49606 µinch) 40 mm (1.575 inch) (3.696 ± 0.0006 inch) (31.49606 µinch)
(2.949 ± 0.0006 inch)
Ra Ra
259-2489 Ø 74.9 ± 0.015 mm
331-3656 (2.949 ± 0.0006 inch)
Table 5
Specifications for Idler Shafts
Idler Shaft Diameters and Surface Textures

Part Diameter of Larger End Surface Texture of Diameter of Smaller End Surface Texture of
Number of Shaft (F) Larger End of Shaft (G) of Shaft (H) Smaller End of Shaft (J)
Ø 129.86 ± 0.05 mm 5.5 µm (216.5354µinch) Ø 89.88 ± 0.02 mm 0.80 µm (31.49606 µinch)
7C-3260
(5.11259 ± 0.00197 inch) Ra (3.53858 ± 0.00079 inch) Ra
Ø 105.88 ± 0.02 mm
250-9947
(4.16850 ± 0.00079 inch)
Ø 89.88 ± 0.02 mm
277-6911
(3.53858 ± 0.00079 inch)
Ø 105.88 ± 0.02 mm
282-8915
(4.16850 ± 0.00079 inch)
329-8192
Ø 161.73 ± 0.05 mm < 3.5 µm Ø 119.814 ± 0.012 mm
430-8140
(6.36731 ± 0.00197 inch) (< 137.7953 µinch) Ra (4.71708 ± 0.00047 inch)
430-8141
Table 6
Specifications for PTO Shafts
PTO Shaft Diameters and Surface Textures

Part Surface Surface Surface Surface
(K) (M) (P) (S)
Number Texture (L) Texture (N) Texture (R) Texture (T)
1.6 µm
Ø 59.946 ± 0.013 mm Ø 63.42 ± 0.013 mm Ø 95.0 ± 0.015 mm Ø 63.42 ± 0.013 mm
4P-3743 (62.99213 µinch)
(2.36007 ± 0.00051 inch) (2.49685 ± 0.00051 inch) (3.74015 ± 0.00059 inch) (2.49685 ± 0.00051 inch)
Ra
Ø 95.0 ± 0.015 mm
289-6329 35 µm 0.2 µm < 3.5 µm 0.2 µm
Ø 57.897 ± 0.05 mm Ø 63.43 ± 0.01 mm (3.74015 ± 0.00059 inch) Ø 63.43 ± 0.01 mm
(1377.953 µinch) (7.87401 µinch) (< 137.7953 µinch) (7.87401 µinch)
(2.27940 ± 0.00197 inch) (2.49724 ± 0.00039 inch) Ø 101.5 ± 0.015 mm (2.49724 ± 0.00039 inch)
290-1630 Ra Ra Ra Ra
(3.99606 ± 0.00059 inch)
1.6 µm
Ø 59.946 ± 0.013 mm Ø 63.42 ± 0.013 mm Ø 95.0 ± 0.015 mm Ø 63.42 ± 0.013 mm
315-3096 (62.99213 µinch)
(2.36007 ± 0.00051 inch) (2.49685 ± 0.00051 inch) (3.74015 ± 0.00059 inch) (2.49685 ± 0.00051 inch)
Ra
Table 7
Sleeve Installation and Machining Procedure

Fuel Pump Adapter Assembly
Note: When you are installing the bearing sleeve, the hole in the bearing sleeve must be aligned with oil passage (B).
291-1998 and 354-1562 485-0316 Pump Adapter Assembly and with 318-4810 Bearing Sleeve
Dimension Description Dimension

A Bore diameter of adapter after sleeve installation 94.056 mm (3.70298 inch)
Table 8
Engine Oil Pump Adapter Assembly
Note: When you are installing the bearing sleeve, the hole in the bearing sleeve must be aligned with oil passage (E). The
hole in the bearing sleeve has a position tolerance of 3.0 mm (0.11811 inch) from datum (1).
348-7075 Engine Oil Pump Adapter Assembly with 348-7074 Bearing Sleeve

C Diameter of bearing bore after sleeving 75.023 mm (2.95366 inch)
Table 9
Former 247-3417 Engine Oil Pump Adapter Assembly with 127-5400 Bearing Sleeve
Current 348-7075 Engine Oil Pump Adapter Assembly 348-7074 bearing sleeve with the dimensions
below

C Diameter of bearing bore after sleeving 75.0 ± 0.055 mm (2.95275 ± 0.00217 inch)
Table 10
Front Adapter Assemblies
Note: When you are installing the bearing sleeve, the hole in the bearing sleeve must be aligned with oil passage (H).
The bearing sleeve should be installed so that the bearing sleeve is flush with surface (G) +/- 0.5 mm (0.019 inch).
348-7076 Front Adapter Assemblies with 348-7074 Bearing Sleeve

F Diameter of bearing bore after sleeving 75.035 mm (2.95413 inch)
Table 11
Former 248-7582 Front Adapter Assemblies with 127-5400 Bearing Sleeve

Rework with 348-7076 Front Adapter Assemblies 348-7074 bearing sleeve with the dimensions
below

F Diameter of bearing bore after sleeving 75.0 ± 0.055 mm (2.95275 ± 0.00217 inch)
Table 12
Low, Medium, and High-Speed Idler Gears
Low, Medium, and High-Speed Idler Gear Assemblies
Part Machined Diameter of Bearing Sleeve After
Installation Depth (J) Surface Texture (K)
Number Installation (I)
307-2402 89.964 ± 0.01 mm (3.54188 ± 0.0004 inch)
2.3 ± 0.5 mm 0.80 µm
312-1676
105.98 ± 0.01 mm (4.1724 ± 0.0004 inch) (0.0905 ± 0.0197 inch) (31.49606 µinch) Ra
312-1677
Table 13
Idler (Cluster) Gear and Shaft
254-5886 Idler (Cluster) Gear with 254-5887 Bearing Sleeve

A Machined Diameter of Bearing Sleeve 75.06 ± 0.01 mm (2.9551 ± 0.0004 inch)
B Installation Depth 2 ± 0.5 mm (0.08 ± 0.02 inch)
C Surface Texture 0.80 µm (31.49606 µinch) Ra
Table 14
Example of cluster gear shaft
328-7113 Cluster Gear Shaft

D Shaft Diameter 74.97 ± 0.01 mm (2.9516 ± 0.0004 inch)
E Surface Texture 0.13 µm (5.11811 µinch) Ra
Table 15
Example of idler and cluster gear
Idler and Cluster Gear Specifications

Part Surface Texture Machined Diameter of Bearing Diameter of Original
Installation Depth (G)
Number (F) Sleeve After Installation (H) Gear Bore (J)
478-5468 0.80 µm
1 ± 0.5 mm 119.93 ± 0.01 mm 128.009 ± 0.013 mm
(31.49606 µinch)
478-5469 (0.03937 ± 0.01969 inch) (4.72164 ± 0.00039 inch) (5.03971 ± 0.00051 inch)
Ra
Table 16
Example of auxiliary drive gear
Auxiliary Drive Gear Specifications

Part Number Diameter of Original Gear Bore (K)
245-1357 95.05 ± 0.025 mm (3.74212 ± 0.00098 inch)
273-3816 101.551 ± 0.025 mm (3.99806 ± 0.00098 inch)
Table 17
Salvage Procedures for Front and Rear Gear Train on 3500

Engines
On 3500 Engines, the bearing sleeves on the front gear train have been improved to increase the life of the sleeve and gear
train reliability. Several refinements have been made to improve the service life and reliability of the rear gear trains.
Improvements to the Front Gear Train

New bearing sleeves were released for the following:
Low Speed Idler Gears
High-Speed Idler Gears
Adapter Assemblies
These bearing sleeves have increased durability and resistance to cavitation erosion and fatigue.
In addition, the bearing sleeve is machined after assembly. The machining of the bearing sleeve provides better control of
the clearance of the bearing sleeve to shaft. The machining also improves bearing resistance to fatigue. The adapter
bearing sleeve needs no machining after assembly.
With the change of the bearing material, the interference fit between the bearing sleeve and gear or bearing sleeve and the
adapter has also changed. The new interference fit will help retain the bearing sleeve in the mating part.
As a result of reconditioning or replacing existing parts, older engines can gain the same benefits as newer engines.
Part Numbers for the Bearing Sleeve
Description Former Bearing Sleeve New Bearing Sleeve

High-Speed Idler Gear Assembly 7N-5243 140-9597
Low Speed Idler Gear Assembly 8N-5301 116-1365
Adapter Assembly 7N-5244 127-5400
Table 18
Affected Engines
The improvements to the 3500 Engines came in three stages. The first stage was the release of the new bearing sleeve for
the low speed idler gear assembly. The engines with this change and the serial numbers are listed in Table 19. All the
attachments that are low speed drives that were made afterOctober 1996have the new bearing sleeves on the front idler
gear assemblies.
Effective Serial Numbers for Low Speed Idler Gear Assemblies
Model 3508 3512 3516

Industrial S/N:68Z874 N/A S/N:71Z324
Marine S/N:69Z717 N/A S/N:72Z518
Generator Set S/N:70Z952 N/A S/N:73Z768
S/N:1313 S/N:4KC567 S/N:3RC1113
Gas (Right Side) S/N:2JF325 S/N:5JD22 S/N:8LD28
S/N:9TG56 S/N:7NJ108 S/N:4EK510
S/N:2JF344 S/N:4KC640 S/N:3RC1201
Gas (Left Side) S/N:9TG123 S/N:5JD30 S/N:8LD38
N/A S/N:7NJ221 S/N:4EK1096
Table 19
The second stage was the release of the new bearing sleeves on all adapter assemblies. All 3500 Engines that were
manufactured after May 1996were built with the new bearing sleeve on the front adapter assemblies.
The third stage was the release of the new bearing sleeve on all the high-speed idler gear assemblies that were
manufactured after May 1997. The serial number ranges for this change are shown in Table 20.
Effective Serial Numbers for High-Speed Adapter Assemblies
Model 3508 3512 3516

Industrial S/N:95Y1019 S/N:49Y836 S/N:27Z776
S/N:96Y1731 S/N:50Y1519 S/N:29Z1235
S/N:7SM85 S/N:4TN101 S/N:4MJ177
Marine
S/N:2BM123 S/N:7HM176 S/N:8KN156
N/A S/N:8EM264 S/N:8CN146
Marine Auxiliary S/N:3DM94 N/A S/N:9AN122
S/N:23Z6906 S/N:24Z8021 S/N:25Z5597
S/N:6PN302 S/N:8RM216 S/N:4XF678
Generator Set S/N:4GM224 S/N:6WN142 S/N:5SJ547
N/A N/A S/N:7RN473
N/A N/A S/N:6HN162
Locomotive S/N:6TJ14 S/N:2WK76 S/N:9KF104
Vehicular S/N:97Y718 S/N:51Y761 S/N:28Z649
Petroleum N/A S/N:1LM142 N/A
S/N:2JF349 S/N:4KC646 S/N:3RC1228
Gas S/N:9TG148 S/N:7NJ303 S/N:4EK1352
N/A N/A S/N:5PN35
D11N
776B S/N:99W3520 N/A N/A
777B
D11R
5130
S/N:7YG2092 N/A N/A
776C
777C
D11R
992G
S/N:2GR744 N/A N/A
776D
777D
789
793 N/A N/A S/N:54Z1170
994
789B
793B N/A N/A S/N:2PK1455
5230
793C
N/A N/A S/N:7TR402
994G
Table 20
Front Gear Train
Option 1 Option 2 Option 3
Idler Gear
Idler Gear High Strength Bearing Medium Strength Bearing
Assembly
Assembly(1) Sleeve Sleeve
144-8263 144-8263 140-9597 7N-5243
7E-0274 144-8263 140-9597 7N-5243
111-8145 144-8263 140-9597 7N-5243
116-3242 116-3242 116-1365 8N-5301
2W-7321 116-3242 116-1365 8N-5301
2W-0548 153-1243 116-1365 8N-5301
420-4042 420-4042 116-1365 8N-5301
Option 1 Option 2 Option 3
Adapter Assembly
Adapter Assembly(2) High Strength Bearing Sleeve Medium Strength Bearing Sleeve
4P-0668 4P-0668 127-5400 N/A
7C-4164 364-6393 127-5400 N/A
7C-4165 7C-4165 127-5400 N/A
7E-6748 7E-6748 127-5400 N/A
7N-5245 7N-5245 127-5400 N/A
7N-5263 278-4287 127-5400 N/A
7N-5263 279-3342 127-5400 N/A
7N-5279 7N-5279 127-5400 N/A
8N-8210 441-3369 127-5400 N/A
107-0779 487-4303 127-5400 N/A
107-7362 364-6393 127-5400 2S-7056
Table 21
(1)
(2) New idler gear assemblies come with bearing sleeves installed and machined.
New adapter assemblies come with bearing sleeves installed.
Table 21 shows the new part numbers for the idler gear and adapter assembly and the former part numbers for the idler gear
and adapter assembly.
Note: All affected adapter assemblies are listed in table 21.
Reconditioning the Components of the Front Gear Train

Three options are available when the idler gear and adapter assembly in the front gear train are being reconditioned.
1. Replace the idler gears and adapters with new parts.
2. Use the original gears and/or adapters with new high strength bearing sleeves.
3. Use the original gears with new bearing sleeves that are medium strength .
The required parts for the rework vary depending on the option that is used to recondition the gear train. Table 21 shows the
required parts for each particular option for rework.
Option 1 - New Assembly

If idler gear and adapter assemblies are replaced with new parts, no further rework is required. The new parts will have new
high strength bearing sleeves installed, and the idler gears are finish machined to size.
Option 2 - Reused Assembly with New High Strength Bearing Sleeve

If original idler gear and/or adapter is reused, new high strength bearing sleeves must be pressed into the gear or the
adapter. Idler gear assemblies must be machined. Refer to the section: "Sleeve Installation and Machining Procedure" within
this document. Adapter assemblies do not require finish machining to be done.
NOTICE
If the required clearance is not maintained, the bearing sleeve
could fail and cause engine damage.
Note: Before installing the gear, make sure that the clearance between the bearing sleeve and the mating shaft meets the
required specifications. High-speed idler gears must have 0.12 ± 0.03 mm (0.005 ± 0.001 inch) clearance between the
bearing sleeve and the shaft. Low speed idler gears must have 0.09 ± 0.03 mm (0.004 ± 0.001 inch) clearance. Prior to
machining the bearing sleeve, measure the shaft and maintain the required clearance.
Option 3 - Reused Assembly with New Medium Strength Bearing Sleeve

Original idler gear and new bearing sleeves that are medium strength with the overlay that is lead tin can be used if there is
no evidence of bearing cavitation or fatigue. If the procedure for machining for the finish cannot be completed on the bearing
that is high strength, use the bearing sleeve that is medium strength. After the bearing sleeves that are medium strength are
installed, no machining is required.
Sleeve Installation and Machining Procedure

When bearing sleeves are replaced, use the installation and the removal procedure in the appropriate Service Manual. The
same removal procedure for the former bearing sleeves is used for new bearings.
The specifications in the Table 22 are for installation and the machining of the inside diameter of the new bearing sleeves.
1. When an idler gear assembly (4) is reconditioned, the bearing sleeve (3) is installed into the gear to depth (C).
2. Machine by honing the inside diameter to the dimension (A)
The illustration shows items for the bearing sleeve in the idler gear assembly. Refer to Table 22 for identification of the items and dimensions.
Specifications for Bearing Sleeve
Dimension Description
90.000 ± 0.010 mm (3.5433 ± 0.0004 inch)(1)(2)
(A)
105.970 ± 0.010 mm (4.1720 ± 0.0004 inch)(3)(2)
(B) The surface of the gear must be square with the bore within 0.05 mm (0.002 inch).
(C) 2.3 ± 0.5 mm (0.09 ± 0.02 inch)
(D) Pitch diameter must be concentric with a total indicator reading(TIR) of 0.15 mm (0.006 inch) or less.
Table 22
(1)
(2) High-speed idler gears.
(3) The surface texture of the inside diameter must be 0.8 micro meter (31.50 micro inch).
Low speed idler gears.

New Part Numbers
Former Part Replace As Option Option Option Option

Quantity Description
Number Needed 1 2 3 4
1 7E-5324 Ring 7E-5324 N/A N/A N/A N/A
4W-4793(2) 7E-3897(1) N/A N/A N/A
7E-3897 7E-3897(1) N/A N/A N/A
2 Camshaft Drive
100-6518 N/A 100-6518 N/A N/A N/A
Gear
101-1369 101-1369 N/A N/A N/A
1-2 101-0242 101-0242 N/A N/A N/A
7N-5257(2) 4P-5440 N/A N/A 112-1554
7E-3894(2) 4P-5440 N/A N/A 112-1554
4P-5440 4P-5440 N/A N/A 112-1554
Idler Gear
2 115-5281 N/A 115-5281 N/A N/A 121-4749
Assembly(3)
112-1554 112-1554 N/A N/A N/A
101-1364 101-1364 N/A N/A N/A
121-4749 121-4749 N/A N/A N/A
7N-5258 N/A 125-9750 125-9750 N/A
4P-5439(2) N/A 125-9750 125-9750 N/A
125-9750 N/A 125-9750 125-9750 N/A
2 115-5283 Bearing Sleeve(3) N/A N/A 15-5283 15-5283 N/A
101-1374 (2)
N/A 125-9751 125-9751 N/A
125-9751 N/A 125-9751 125-9751 N/A
121-4750 N/A 121-4750 121-4750 N/A
1N-3986 (4)
4P-5091 4P-5091 4P-5091 101-1368
4P-5091 4P-5091 4P-5091 4P-5091 101-1368
2 Thrust Washer N/A
101-2983 101-2983 101-2983 101-2983 101-1368
101-1368 101-1368 101-1368 101-1368 N/A
4 0S-1595 Bolt 0S-1595 N/A N/A N/A N/A
4W-4998 4P-5437 4P-5437 N/A N/A
4W-5014 4P-5456 4P-5456 N/A N/A
4P-5437 Shaft of the Cluster 4P-5437 4P-5437 N/A N/A
1 N/A
4P-5456 Gear(5)(6) 4P-5456 4P-5456 N/A N/A
101-1366 101-1366 101-1366 N/A N/A
101-1378 101-1378 101-1378 N/A N/A
1N-4054 (2)
4P-5090 4P-5090 N/A 112-1552
4P-5090 4P-5090 4P-5090 N/A 112-1552
2 101-2982 Idler Gear Shaft (3)
N/A 101-2982 101-2982 N/A 112-1552
112-1552 112-1552 112-1552 N/A N/A
101-1367 101-1367 101-1367 N/A N/A
1A-5822
4 Bolt 1B-4367 1B-4367 1B-4367 1B-4367 1B-4367
1B-4367
2 8S-2331 Bolt 8S-2331 N/A N/A N/A 8S-2331
1 7N-6983 Bearing Sleeve (6)
N/A N/A 4P-5438 4P-5438 4P-5438
7N-2864 N/A 4P-5460 4P-5460 4P-5460
4P-5438 N/A 4P-5438 4P-5438 4P-5438
4P-5460 N/A 4P-5460 4P-5460 4P-5460
115-5279 N/A 115-5279 115-5279 115-5279
101-1372 N/A 101-1372 101-1372 N/A
1D-4609 9X-8887 9X-8887 9X-8887 9X-8887
2 Bolt 9X-8887
9X-8887 N/A N/A N/A N/A
2 5P-8246 Hard Washer 5P-8246 N/A N/A N/A N/A
7E-8777 (2)
4P-5459 N/A N/A N/A
7E-3891 (2)
4P-5457 N/A N/A N/A
7E-8779 (2)
107-2477 N/A N/A N/A
7E-8781 (2)
4P-5458 N/A N/A N/A
4P-5459 4P-5459 N/A N/A N/A
4P-5457 4P-5457 N/A N/A N/A
4P-5441 (2)
Cluster Gear 107-2477 N/A N/A N/A
1 N/A
4P-5458 Assembly(5)(6) 4P-5458 N/A N/A N/A
107-2477 107-2477 N/A N/A N/A
115-5277 115-5277 N/A N/A N/A
101-1363 101-1363 N/A N/A N/A
101-1381 (2)
114-3372 N/A N/A N/A
114-3372 114-3372 N/A N/A N/A
101-1377 101-1377 N/A N/A N/A
7N-5254 101-1365 101-1365 101-1365 101-1365
1 Thrust Plate N/A
101-1365 101-1365 101-1365 101-1365 101-1365
2 4W-4586 Plate 4W-4586 N/A N/A N/A N/A
4 0L-1351 Bolt N/A 0L-1351 N/A N/A N/A
12 3S-1307 Bolt 3S-1307 N/A N/A N/A N/A
2W-2895 2W-2895 N/A N/A N/A N/A
1 Crankshaft Gear
101-1370 101-1370 N/A N/A N/A N/A
Table 23
(1)
The 7E-3897 Camshaft Drive Gear can be directly replaced with a 100-6518 Camshaft Drive Gear in any 3500 Engine application. However, the
(2) 100-6518 Camshaft Drive Gear must be used in all 3516 S/N:4MJ34 Marine Engines unless 8 pitch gears are used.
(3) Canceled
New idler gear assemblies (4) are ready for installation. Former idler shafts (9) and new bearing sleeves (5) cannot be used together unless both parts
are reconditioned. If the bearing sleeve is serviced separately, refer to the "All Camshaft Idler Gear and Cluster Gear Assemblies" section in this
(4) guideline.
(5) This part is not Canceled.
New cluster gear assemblies (15) are ready for installation. Former shafts of cluster gears (8) and new bearing sleeve (12) cannot be used together
unless both parts are reconditioned. If the sleeve bearing is serviced separately, refer to "All Camshaft Idler Gear and Cluster Gear Assemblies"
(6) section in this Guideline.
Order the part number that is specific to the engine application.
During rebuild, refer to Table 23 to determine which parts must be replaced. The parts that are listed in the Replace as
Needed column should be checked during each rebuild. The parts that are listed under the column, Option, are the parts
that are required for that particular option for rework. Some parts are not common with all engine models. Those parts are
the assemblies of the cluster idler gear, the bearing sleeves, and the shafts. For these parts, order the part number that is
required for the specific engine model. Not all the parts in the gear group have changed.
Improvements to the Rear Gear Train

Several changes were made to improve the service life and reliability of the rear gear train. These changes include new
gears, bearing sleeves, and gear shafts. As a result of reconditioning or replacing existing parts, older engines can gain the
same benefits as newer engines.
The following list of improvements is divided into two sections: 3500 and 3500B Changes that affect both series of engines
will be discussed in each section.
3500
New drive gears for the cam, idler gears, and cluster gears are used. The new parts now have a deeper depth of the
case of hardened material. The new parts are case carburized.
A new 100-8310 Rear Gear Gp has been developed. The new rear gear group is a direct replacement for the former
4W-5906 Rear Gear Gp. The new gear group is now effective with all the 3516 marine engines. The serial number
4MJ34 is adapted with the new gear group. The gear group is adaptable to all earlier engines. The new 100-6518
Camshaft Drive Gear that is heavier has increased rotational inertia. This improvement has lowered the mesh torques
for gear to gear, which has resulted in an increase of the service life of the gear.
Camshaft Drive Gear. Gear (A) on left shows a cross section of 100-6518 Camshaft Drive Gear. Gear (B) on right shows 7E-3897 Camshaft Drive Gear.
New 8 pitch gears are available for the small cluster gear, idler gear, and the camshaft drive gear for 3516-Phase II
Marine and Generator Set Engines. The 8 pitch gears can handle more torque than the former 10 pitch gears. This
new gear results in increased service life of the gear. This change is not retrofitted to the earlier engines because of a
change to the flywheel housing for allowing the larger gears.
The bearing sleeves in the cluster gears and idler gears have been changed from aluminum bearing sleeves with steel
backing to bronze bearing sleeves with steel backing. This change will increase the resistance to fatigue for the
bearing.
The cluster and idler gear shafts are slightly larger in diameter. This change reduces the clearance between the shaft
and the sleeve bearings to minimize the wobble of the gear.
The new shafts for the cluster gear and the idler gear have two smaller oil supply holes instead of one hole with a large
diameter. This improvement will provide better distribution of the oil to the bearing sleeve.
Idler gear shafts have a thicker flange to prevent breakage at the corners of the half flange.
The bolt pattern and shaft diameter of the idler gear shaft has been changed. The new shaft has a bolt hole pattern
with three bolt holes instead of two bolt holes to secure the idler shaft to the block. The new idler shaft uses three 5/8-
11 bolts. The former idler shaft used two 5/8-11 or two 1/2-13 bolts. The shaft diameter has also changed to accept the
new bolt hole pattern. 3500 and 3500B cylinder blocks are now common cylinder blocks.
The 125-9751 bronze bearing sleeve with a steel backing has been released with a larger outside diameter to increase
the interference fit between the gear and sleeve. This bearing sleeve will result in better retaining of the bearing sleeve
in the camshaft idler gear assembly.
The interference fit between the small cluster gears and the large cluster gears has been increased. This increase will
provide the retention of the joint and will reduce the risk of slippage of the joint of the gear.
The cylinder block and the idler gear thrust washers have been changed to accept the three bolt hole pattern.
3500B
With the release of the 3500B, the pitch of the small cluster, idler, and camshaft drive gear has been changed from 10
to 8. The reduced pitch provides better carrying capability for torque.
The interference fit between the small cluster gears and the large cluster gears has been increased. This increase will
provide the retention of the joint and will reduce the risk of slippage of the joint of the gear.
The following sections in this guideline describe the specifications and procedures to recondition existing parts to take
advantage of the listed improvements.
Engines That Were Affected By The Improvements

The improvements to the 3500 Engines came in several stages. The first stage included the replacement of the former gears
with the new case carburized gears. The engines and the serial numbers that were affected by this change are listed in
Table 24.
The second stage incorporated the introduction of the new bronze bearing sleeves with steel backing, the change in
diameter and number of oil feed holes to the cluster and idler shafts, and the change to provide a thicker flange on the idler
shaft. Also, the bolts that secure the idler shaft were changed from 1/2-13 to 5/8-11. Table 25 lists the engines that are
affected by these changes. Engines that are first listed in the Table 25 include the change to the case carburized gears.
The third stage included the increase in the number of bolts that secure the idler shaft from two bolts to three bolts. Also, a
common block was provided for 3500 and 3500B Engines. Refer to Special Instruction, SEHS9826, "Ordering "Series B"
Replacement Cylinder Blocks for 3500 Series Engines" for more information. Table 26 lists the engines and the serial
numbers that are affected by this change.
The next stage was to release 8 pitch gears for 3516-Phase II Marine and Generator Set Engines. The effective serial
numbers for the affected engines are listed in Table 27.
Next, the interference fit between the idler gear and bearing sleeve was increased. Table 28 lists the engines and the serial
numbers that are affected by this change.
Next, the interference fit between the small cluster gear and the large cluster gear was increased. The effective serial
numbers for the affected engines are listed in Table 29.
Note: Not all serial numbers are listed in Table 29. All engines that were manufactured after June 1995contain cluster gears
with an increased interference fit.
Effective Serial Numbers for Case Carburized Gears in Rear Gear Trains (Camshaft Drive)
Model 3508 3512 3516

Industrial N/A S/N:65Z715 S/N:71Z297
Marine N/A S/N:66Z423 S/N:72Z415
Generator Set (low speed) N/A S/N:67Z794 S/N:73Z405
D11N
776B S/N:99W1942 N/A N/A
777B
789 N/A S/N:54Z661 N/A
Table 24
Effective Serial Numbers for Changes to the Cluster and Shaft of the Idler Bearing Sleeve
Model 3508 3512 3516

Industrial S/N:68Z776 S/N:65Z724 S/N:71Z302
S/N:29Z967
Marine S/N:96Y1147 S/N:50Y948 S/N:4MJ34
S/N:5MJ33
Marine S/N:69Z562 S/N:66Z434 S/N:72Z427
S/N:23Z3671 S/N:24Z3920 S/N:25Z226
Generator Set
S/N:1ZF593 S/N:3YF604 S/N:4XF382
Generator Set (low speed) S/N:70Z775 N/A S/N:73Z463
Locomotive N/A N/A S/N:9KF56
D11N
776B S/N:99W2752 N/A N/A
777B
785 N/A S/N:96Z740 N/A
789 N/A S/N:54Z719 N/A
Table 25
Effective Serial Numbers for Idler Shafts with Three Bolt Hole Patterns
Model 3508 3512 3516

S/N:29Z1120
Marine S/N:96Y1485 S/N:50Y1317 S/N:4MJ162
S/N:5MJ33
S/N:25Z4283
Generator Set S/N:23Z5701 S/N:24Z6028 S/N:4XF572
S/N:5SJ289
Generator Set (low speed) S/N:70Z887 S/N:67Z1185 S/N:73Z682
Locomotive S/N:6TJ12 S/N:2WK40 S/N:9KF80
S/N:2JF302 S/N:4KC557 S/N:3RC1072
Gas
S/N:9TG27 S/N:5JD19 S/N:4EK374
D11N
776B S/N:99W3447 N/A N/A
777B
D11R
5130
S/N:7YG959 N/A N/A
776C
777C
785 N/A S/N:96Z912 N/A
785B N/A N/A S/N:4WJ535
789
793 N/A S/N:54Z1069 N/A
994
789B
793B N/A S/N:2PK679 N/A
5230
Table 26
Effective Serial Numbers for the Introduction of 8 Pitch Gears
Model 3508 3512 3516

Marine N/A N/A S/N:4MJ150
S/N:5SJ162
Generator Set N/A N/A
S/N:4XF460
Table 27
Effective Serial Numbers for 125-9751 Bearing Sleeve
Model 3508 3512 3516

S/N:29Z1168
Marine S/N:96Y1563 S/N:50Y1383
S/N:5MJ33
S/N:23Z6191 S/N:25Z4726
Generator Set S/N:24Z6689
S/N:8TL3 S/N:4XF606
Generator Set (low speed) S/N:70Z925 S/N:67Z1286 S/N:73Z701
S/N:9KF103
Locomotive S/N:6TJ14 N/A
S/N:5PN35
S/N:2JF330 S/N:4KC593 S/N:3RC1126
Gas S/N:9TG67 S/N:5JD23 S/N:4EK600
S/N:4WD13 S/N:7NJ133 S/N:8LD28
D11N
776B S/N:99W3487 N/A N/A
777B
D11R S/N:7YG1438 N/A N/A
5130
776C
777C
785 N/A S/N:96Z913 N/A
785B N/A S/N:4WJ643 N/A
789
793 N/A N/A S/N:54Z1117
994
789B
793B N/A N/A S/N:2PK906
5230
Table 28
Effective Serial Numbers for the Increased

Interference Fit Cluster Gear.
Model 3508 3512 3516

Marine N/A N/A S/N:8KN68
S/N:5SJ353
Generator Set N/A N/A
S/N:4XF593
Locomotive N/A N/A S/N:5PN35
S/N:5JD20 S/N:4EK371
Gas N/A
S/N:7NJ73 S/N:8LD28
785B N/A S/N:4WJ545 N/A
789B
793B N/A N/A S/N:2PK680
5230
Table 29
Reconditioning the Components of the Rear Gear Train

Four options are available for reconditioning the drive group for the rear gear train. These options are listed as following.
1. Replace all the parts in the gear train.
2. Use the original gears with new bronze bearing sleeves and shafts.
3. Use the original shafts and gears with new bronze bearing sleeves.
4. This option is for the required rework, when a replacement block is used.
The parts that are required for the rework may vary depending on the option that is used to recondition the gear train. Table
23 shows the part number, under the column, Option, which is required for that particular option for rework. Each option is
explained in more detail below.
Option 1
If all the gears and the shafts in the rear gear train are replaced, then modifying or reworking of the bolt holes which retain
the idler gear shaft (8) is the only action that is needed. If the current engine block has 5/8-11 threaded holes or a pattern of
three bolt holes, then no modification is necessary. If the holes are 1/2-13, then the holes must be drilled and tapped
according to the "Rework of Bolt Holes in Cylinder Block" section in this guideline.
Option 2
If the original gears are used again, then new bronze bearing sleeves must be pressed into the gear and machined to a
finish. The "All Camshaft Idler Gear and Cluster Gear Assemblies" section in this guideline provides a procedure for this
operation. Also, check the bolt holes in the cylinder block that retain idler gear shaft (9) to determine if the bolt holes should
be reworked.
Option 3
If the original shafts and gears are used again with the new bronze bearing sleeves, the new bearing sleeves must be
machined after being pressed into the gear.
Idler gear shafts (8) and the shaft for the cluster gear (8) must also be reworked for a second oil hole, if necessary. This
rework procedure is contained in the "Reworking Idler and Cluster Gear Shafts" section.
Option 4
If the original cylinder block has two 1/2-13 or two 5/8-11 tapped holes for the shaft of the rear camshaft idler gear and the
replacement block has three tapped holes, new idler gears (3) and idler gear shafts (8) are required. The original cluster
gear (14) and the shaft of the cluster gear (7) can be used again. If the original cluster gear assembly is used again, then
new bronze bearing sleeves must be pressed into the gear and machined to a finish. The "All Camshaft Idler Gear and
Cluster Gear Assemblies" section provides a procedure for this operation. The shaft of the cluster gear (8) must also be
reworked for a second oil hole, if necessary.
Note: Maintain the correct clearance between the shaft and idler gear and cluster gear. The clearance in diameter between
the shaft and idler gear is 0.060 ± 0.020 mm (0.0024 ± 0.0008 inch). The clearance in diameter between the shaft and
cluster gear is 0.070 ± 0.020 mm (0.0028 ± 0.0008 inch). Prior to machining the bearing sleeve, take a measurement from
the shaft and maintain the above clearance.
Rework of Bolt Holes in Cylinder Block

One improvement to the gear group was the increase of the size of the bolts (9) that retain the idler shaft to the cylinder
block. This rework procedure contains the tool list, instructions, and dimensions for drilling and tapping the bolt holes for the
idler shaft.
Reconditioning the bolt holes of the idler shaft in the block is an acceptable repair, and will cost less than replacing the
cylinder block.
Tooling
The illustration shows the tools that are required for the rework procedure. Refer to Table 30 for the part numbers and the description.
Required Tooling
Item Quantity Part Number Description

N/A 1 4C-9992(2) Pilot
(20) 1 1P-3048 Tap Wrench
(21) 1 9U-5034(2) Tap for Bottoming 5/8-11thd.
(22) 2 1A-5822(1) Bolt, 1/2-13 thd., 69.9 mm (2.75 inch)
(23) 1 1B-4367(2) Bolt, 5/8-11 thd, 69.9 mm (2.75 inch) long.
(24) 1 4C-9993(2) Guide Plate
(25) 2 6V-4857 Lock Screw
(26) 1 4C-9997(2) Drill Bushing 16.13 mm (0.635 inch) (pilot for 15.88 mm (0.625 inch) tap)
(27) 1 4C-9996(2) Drill Bushing 15.88 mm (0.625 inch)
(30) 1 9U-5033(2) Core Drill, four fluted 13.49 mm (0.531 inch)
Table 30
(1)
(2) Bolts that are used for installing the original idler shaft
This tool is included in the 4C-9991 Tool Group for Retrofitting of Idler Shaft.
Procedure
The illustration shows the installation of the guide plate onto the cylinder block.
(24) Guide Plate
(28) Drill Bushing 13.49 mm (0.531 inch)
1. Install bearing sleeve (28) and (29) into guide plate (24).
The illustration shows the installed guide plate (24).
(22) Bolt, 1/2-13 thd., 69.9 mm (2.75 inch)
(24) Guide Plate
2. Mount the guide plate (24) with two 1A-5822 Bolts (22) that were used to retain the idler shaft. Using both bolts will
correctly position the guide plate. Tighten the bolts to 105 ± 20 N·m (75.0 ± 15.0 lb ft). After the bolts are tight, remove
the bolt from bearing sleeve (28).
Use a heavy-duty drill with variable speed.
3. Drill the first hole with core drill (30) with a heavy-duty drill with variable speed. For best results and longest life of the
drill, run the drill at approximately 440 rpm. The hole is drilled until the core drill contacts the bottom of the original
hole. The speed of the motor of the drill will increase when the drill contacts the bottom of the hole.
4. Clean the debris from the drilled hole.
Installing the guide bushing for tapping
(26) Drill Bushing 16.13 mm (0.635 inch) (pilot for 15.88 mm (0.625 inch) tap)
5. Remove 13.49 mm (0.531 inch) bearing sleeve (28), and install 16.13 mm (0.635 inch) bearing sleeve (26). Bearing
Sleeve (26) is used as a pilot for the 5/8-11 tap.
Use a fluid for tapping during this process.
(20) Tap Wrench
(21) Tap for Bottoming 5/8-11 thd.
6. Tap the drilled hole with the 5/8-11 tap for bottoming (21), until the tap comes into contact with the bottom of the hole.
Use liberal amounts of fluid for tapping during the process. When the process is complete, remove the tap, and clean
the hole.
A recommended fluid for tapping is TAP MAGIC. For the address of a local supplier, contact the following.
TAP MAGIC
Steco Corporation
P.O. Box 2238
Little Rock, AR 72203 (USA)
http://www.steco.com/
Install a new 5/8-11 bolt, and rework the remaining hole.
(23) Bolt, 5/8-11 thd. 69.9 mm (2.75 inch) long.
7. Remove bearing sleeve (26), and install 15.88 mm (0.625 inch) bearing sleeve (27) into the guide plate. Install 1B-
4367 Bolt (23), and tighten to 105 ± 20 N·m (75.0 ± 15.0 lb ft).
8. Remove 1A-5822 Bolt (22), and drill bushing (29). Install new drill bushing (28).
9. Repeat Steps 3 through 6.
10. After the second hole is drilled and tapped, remove guide plate (24). Remove any burrs or sharp edges that would
prevent the idler shaft from correctly seating against the cylinder block.
11. Install the idler shaft and thrust washer. Refer to "Bolt Torque" in the next section for tightening specifications.
Bolt Torque
Tighten the bolts (9) that are retaining the idler gear assembly (3) to the proper torque.
The illustration shows locations of the bolts and the idler shafts of the rear gear trains for 3512 and 3516 Engines.
(3) Idler Gear Shaft
(9) Bolt.
(8) Idler Shaft
Earlier rear gear trains used 1/2-13 1A-5822 Bolts which were tightened to 135 ± 15 N·m (100.0 ± 11.0 lb ft).
Current rear gear trains use 5/8-11 1B-4367 Bolts which are tightened to 240 ± 20 N·m (176.0 ± 15.0 lb ft). These bolts are
used in newer models, or rear groups which were salvaged by tapping the holes to 5/8-11.
Note: Add this new information on bolt tightening to the module for specifications and the module for Disassembly and
Assembly in the appropriate Service Manuals.
Reworking Idler and Cluster Gear Shafts

This procedure is for reworking idler gear shaft (9) and the shaft of the cluster gear (8). If the original shafts ( 1N-4054 Idler
Shaft, 4W-4998 Gear Shaft, or 4W-5014 Idler Shaft) are used again, then the shafts must be reworked to provide a second
oil hole. This oil hole is made by extending the current oil hole through to the other side of the shaft.
The oil hole of the shaft can be drilled on a small drill press. The shaft must be clamped in a vise. The speed of the spindle
should be approximately 440 rpm. Illustrations 93 and 94 show the new style of shafts which have through oil holes. Use the
following procedure to add the second oil hole.
The new idler shaft is shown on the left. The old idler shaft is shown on the right.
The new shaft of the cluster gear is shown on the left. The old shaft of the cluster gear is shown on the right.
1. Clamp the shaft in a vise.

Note: Do not use a solid carbide drill bit.
2. Use the existing oil hole as a pilot to drill the new oil hole. Use a 5.94 mm (0.234 inch) carbide tipped drill bit, and drill
approximately 1.5 mm (0.06 inch) into the shaft.
3. Remove the carbide drill bit, and change to a 5.94 mm (0.234 inch) cobalt drill bit. Drill through the shaft. Use liberal
amounts of cutting fluid to cool the drill bit.
4. Chamfer the oil hole with a carbide burr to remove any burrs. If burrs are not removed, then burrs can damage the
bearing sleeves.
All Camshaft Idler Gear and Cluster Gear Assemblies

When bearing sleeves are replaced, use the installation and the removal procedure in the Service Manual. The same
procedure is used for the removal of the bearings for both the former style and the new style. Former idler gears and idler
shafts CANNOT be mixed with new idler gear assemblies and idler shafts. If a new idler gear assembly is used, then the
assembly should be installed with a new idler shaft.
1. During the reconditioning of the cluster gear assembly (15), install the bearing sleeve (12) into the gear (15) to the
depth (B). During reconditioning of the idler gear assembly (4), install the bearing sleeve (5) into the gear (4) to the
depth (E).
The illustration shows an assembly of a balancer gear. Refer to Table 31 for reference dimensions.
The illustration shows an idler gear assembly. Refer to Table 31 for reference dimensions.
2. After the bearing sleeve is installed, then hone the inside diameter to dimension (A) for the cluster gear or the idler
gear.
Specifications for Installing and Machining Bearing Sleeves
Item Description
75.060 ± 0.010 mm (2.9550 ± 0.0004 inch)(1)
(A)
81.060 ± 0.010 mm (3.1913 ± 0.0004 inch)(1)(2)
(B) 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
(C) Pitch diameter must be concentric with a total indicator reading (TIR) of 0.15 mm (0.006 inch)or less.
(D) The surface of the gear must be square with the bore within 0.05 mm (0.002 inch).
(E) 1.00 ± 0.25 mm (0.040 ± 0.0010 inch)
(F) Pitch diameter must be concentric with a total indicator reading (TIR) of 0.12 mm (0.005 inch) or less.
Table 31
(1)
(2) The surface texture of the inside diameter must be 0.8 µm (32 µinch).
This dimension is for the inside diameter of the bearing sleeve for 112-1554 Idler Gear As, 101-1364 Idler Gear As, and 121-4749 Gear As for use
with 125-9751 Bearing Sleeve and 121-4750 Bearing Sleeve.
Idler Gear Bearing Sleeve Machining and Salvage

The process and tool recommendations to machine bronze-faced, steel-backed replacement bearing sleeve for stub shaft
mounted idler gears on Cat engines. This procedure is a robust and repeatable process to salvage idler gears. If the
procedures found in this guideline are followed, bearing sleeves can successfully be pressed and machined into idler gears.
It is critical to the gear assembly that the surface texture and diameter are checked 100% and are within specifications.
When setting up and locating the gear in the machine, it is critical that the Pitchline TIR (process datum location), and
Perpendicular TIR are checked. The locating gage pins for the pitch line must be used (refer to Table 32 and 33).
Failure to align the bearing sleeve for machining and check required machining specifications, can cause gear train
failures.
The surface texture on the inside diameter after machining shall not exceed 0.80 µm (31.49606 µinch) Ra on any
bearing sleeve.
Shafts must also meet the specification for reuse.
Machine the bearing sleeve to print tolerance found in Table 32 and 33.
The machining process must use the pitch line of the gear for locating.
Specifications
The surface texture on the inside diameter after machining shall not exceed 0.80 µm (31.49606 µinch) Ra on any bearing
sleeve in Table 32 and 33.
Idler Gear and Shaft Specifications for Bronze Backed Bearing Sleeve
Bearing
Gear As
Sleeve Nominal Machined Pitchline Max Gear Gear Gage Bearing Sleeve
Part
Part Bearing Sleeve I.D. TIR(1) Face TIR(2) Pin Size(s) Depth in the Gear
Number
Number
4P-3130
9Y-1539 150.002 ± 0.002 mm 10 mm 3 ± 0.5 mm
130-5478 N/A N/A
432-4362 (5.90558 ± 0.00008 inch) (0.39370 inch) (0.11811 ± 0.01968 inch)
512-3024
75.06 ± 0.01 mm 0.12 mm 0.05 mm 4.7625 mm 1 ± 0.25 mm
4P-5440 125-9750
(2.95511 ± 0.00039 inch) (0.00472 inch) (0.00197 inch) (0.18750 inch) (0.03937 ± 0.00984 inch)
4.7625 mm
(0.18750 inch)
and the Gear
75.06 ± 0.01 mm 0.15 mm 0.05 mm 1.5 ± 0.5 mm
4P-5457 4P-5460 2-gage pin
(2.95511 ± 0.00039 inch) (0.00591 inch) (0.00197 inch) (0.05906 ± 0.01968 inch)
size is
6.35 mm
(0.25000 inch)
4.7625 mm
(0.18750 inch)
and the Gear
75.06 ± 0.01 mm 0.15 mm 0.05 mm 1.5 ± 0.5 mm
4P-5458 4P-5460 2-gage pin
size is
6.35 mm
(0.25000 inch)
5 mm
(0.19685 inch)
and the Gear
75.06 ± 0.01 mm 0.15 mm 0.05 mm 1.5 ± 0.5 mm
4P-5459 4P-5438 2-gage pin
size is
6.35 mm
(0.25000 inch)
6 mm
(0.23622 inch)
75.06 ± 0.01 mm 0.15 mm 0.05 mm and the Gear 1.5 ± 0.5 mm
101-1363 101-1372
(2.95511 ± 0.00039 inch) (0.00591 inch) (0.00197 inch) 2-gage pin (0.05906 ± 0.01968 inch)
size is 5 mm
(0.19685 inch)
81.06 ± 0.01 mm 0.15 mm 0.1 mm 6 mm 1 ± 0.25 mm
101-1364 125-9751
6 mm
(0.23622 inch)
75.06 ± 0.01 mm 0.15 mm and the Gear 1.5 ± 0.5 mm
101-1377 4P-5460 N/A
(2.95511 ± 0.00039 inch) (0.00591 inch) 2-gage pin (0.05906 ± 0.01968 inch)
size is 5 mm
(0.19685 inch)
5 mm
0.15 mm
(0.19685 inch)
(0.00591 inch)
and the Gear
75.06 ± 0.01 mm and 0.1 mm 0.05 mm 1.5 ± 0.5 mm
107-2477 4P-5438 2-gage pin
size is
for the inside
6.35 mm
gear
(0.25000 inch)
81.06 ± 0.01 mm 0.12 mm 0.05 mm 4 mm 1 ± 0.25 mm
112-1554 125-9751
0.15 mm 6 mm
(0.00591 inch) (0.23622 inch)
75.06 ± 0.01 mm and 0.1 mm 0.05 mm and the Gear 1.5 ± 0.5 mm
114-3372 101-1372
for the inside size is 5 mm
gear (0.19685 inch)
81.06 ± 0.01 mm 0.12 mm 0.1 mm 8 mm 1 ± 0.25 mm
127-4628 125-9751
0.15 mm 8 mm
(0.00591 inch) (0.31496 inch)
136-3277 101-1372
gear (0.47244 inch)
0.15 mm
5 mm
(0.00591 inch)
(0.19685 inch)
128-2661 (3)
63.566 ± 0.013 mm and 0.1 mm 0.1 mm 2.8 ± 0.5 mm
149-9107 and Gear 2 is
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.11024 ± 0.01968 inch)
6 mm
for the inside
(0.23622 inch)
gear
81.06 ± 0.01 mm 0.12 mm 0.1 mm 6 mm 1 ± 0.25 mm
175-5197 125-9751
0.15 mm 6 mm
(0.00591 inch) (0.23622 inch)
175-5200 101-1372
gear (0.19685 inch)
0.15 mm 8 mm
(0.00591 inch) (0.31496 inch)
185-1495 71.035 ± 0.013 mm and 0.1 mm 0.1 mm and the Gear 2.5 ± 0.5 mm
224-9664
331-6185 (2.79665 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) 2-gage pin (0.09843 ± 0.01968 inch)
gear (0.39370 inch)
71.035 ± 0.013 mm 0.1 mm 0.1 mm 8 mm 2.6 ± 0.5 mm
185-1497 224-9664
0.15 mm 5 mm
(0.00591 inch) (0.19685 inch)
128-2661 (3) 63.566 ± 0.013 mm and 0.1 mm 0.1 mm and Gear 2- 2.8 ± 0.5 mm
187-8979
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) gage pin size (0.11024 ± 0.01968 inch)
for the inside is 6 mm
gear (0.23622 inch)
0.15 mm
5 mm
(0.00591 inch)
(0.19685 inch)
128-2661(3)
63.566 ± 0.013 mm and 0.1 mm 0.1 mm 2.8 ± 0.5 mm
200-2454 and Gear 2 is
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.11024 ± 0.01968 inch)
6 mm
for the inside
(0.23622 inch)
gear
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm Center the bearing
206-4225 209-8621
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) sleeve in the gear
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm Center the bearing
207-8211 209-8621
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) sleeve in the gear
0.15 mm 8 mm
(0.00591 inch) (0.31496 inch)
226-6036 226-6052
gear (0.39370 inch)
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm 3 ± 0.5 mm
228-5814 209-8621
0.15 mm 8 mm
(0.00591 inch) (0.31496 inch)
230-6202 224-9664
gear (0.15748 inch)
137.91 mm 0.25 mm 0.1 mm 10 mm 1.5 ± 0.5 mm
243-3008 243-3007
(5.42952 inch) (0.00984 inch) (0.0039 inch) (0.39370 inch) (0.05906 ± 0.01968 inch)
0.15 mm 8 mm
(0.00591 inch) (0.31496 inch)
75.06 ± 0.01 mm and 0.1 mm 0.1 mm and the Gear 2 2 ± 0.5 mm
254-5886 254-5887
(2.95511 ± 0.00039 inch) (0.0039 inch) (0.0039 inch) gage pins size (0.07874 ± 0.01968 inch)
for the inside is 10 mm
gear (0.39370 inch)
0.15 mm 6 mm
(0.00591 inch) (0.23622 inch)
261-3133 101-1372
gear (0.19685 inch)
81.06 ± 0.01 mm 0.12 mm 0.05 mm 6 mm 1 ± 0.25 mm
261-3137 125-9751
0.15 mm 8 mm
(0.00591 inch) (0.31496 inch)
261-3443 226-6052
gear (0.39370 inch)
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm 3 ± 0.5 mm
261-3445 209-8621
0.15 mm 4.7625 mm
(0.00591 inch) (0.18750 inch)
271-5656 128-2661(3)
gear (0.19685 inch)
0.15 mm 4.763 mm
(0.00591 inch) (0.18752 inch)
128-2661(3) 63.566 ± 0.013 mm and 0.1 mm 0.1 mm and the Gear 0.38 ± 0.25 mm
300-5575
gear (0.19685 inch)
89.965 ± 0.01 mm 0.1 mm 0.1 mm 10 mm 2.3 ± 0.5 mm
307-2402 307-2403
6 mm
(0.23622 inch)
310-3177 101-1372
size is 5 mm
(0.19685 inch)
105.98 ± 0.01 mm 0.1 mm 0.1 mm 10 mm 2.3 ± 0.5 mm
312-1676 312-1678
105.98 ± 0.01 mm 0.1 mm 0.1 mm 8 mm 2.3 ± 0.5 mm
312-1677 312-1678
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm 3 ± 0.5 mm
320-6198 209-8621
6 mm
(0.23622 inch)
128-2661(3) 63.566 ± 0.013 mm 0.1 mm 0.1 mm and the Gear 2.8 ± 0.5 mm
352-9728
size is 6 mm
(0.23622 inch)
6 mm
(0.23622 inch)
63.566 ± 0.013 mm 0.1 mm 0.1 mm and the Gear Center the bearing
361-8233 128-2661(3)
(2.50259 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) 2-gage pin sleeve in the gear
size is 6 mm
(0.23622 inch)
81.06 ± 0.01 mm 0.15 mm 0.1 mm 6 mm 1 ± 0.25 mm
369-9356 125-9751
0.15 mm 6 mm
(0.00591 inch) (0.23622 inch)
369-9357 101-1372
gear (0.19685 inch)
10 mm
(0.39370 inch)
386-2938 101-1372
size is 8 mm
(0.31496 inch)
50.857 ± 0.013 mm 0.05 mm 6 mm 1.5 ± 0.5 mm
417-4615 417-4616 N/A
50.857 ± 0.013 mm 0.05 mm 6 mm 1.5 ± 0.5 mm
417-4617 417-4618 N/A
478-5468 119.93 ± 0.01 mm 0.1 mm 0.1 mm 10 mm 1.0 ± 0.5 mm
476-5463
478-5469 (4.72 ± 0.00039 inch) (0.00394 inch) (0.00394 inch) (0.39370 inch) (0.03937 ± 0.01968 inch)
Table 32
(1)
(2) Maximum Total Indicator Runout (TIR) tolerance read at the gage pins as the gear is rotated in the lathe.
(3) Maximum Total Indicator Runout (TIR) tolerance read on the face of the gear bore as the gear is rotated in the machine.
131-7123(prefinished bore) is a service replacement for 128-2661. Bearing sleeve dimensions are: 63.595 ± 0.045 mm (2.5037 ± 0.0018 inch).
Note: All the bearing sleeves in Table 32 are Steel Backed Bronze Bearing Sleeves.
Idler Gear and Shaft Specifications for Aluminum Backed Bearing Sleeves
Bearing
Gear As
Sleeves Nominal Machined Pitchline Max Gear Gear Gage Bearing Sleeve
Part
Part Bearing Sleeves I.D. TIR(1) Face TIR(2) Pin Size(s) Depth in the Gear
Number
Number
35.034 ± 0.038 mm 4.7625 mm 1.12 ± 0.25 mm
2W-4087 6N-0977 N/A N/A
(1.37929 ± 0.00150 inch) (0.18750 inch) (0.04409 ± 0.00984 inch)
7E-0274
7N-5243 90.0 ± 0.01 mm 0.15 mm 0.1 mm 6 mm 2.3 ± 0.5 mm
7N-5241
140-9597 (3.54330 ± 0.00039 inch) (0.00591 inch) (0.0039 inch) (0.23622 inch) (0.09055 ± 0.01968 inch)
144-8263
7E-3894 7N-5258 75.000 ± 0.055 mm 4.7625 mm 1.0 ± 0.25 mm
N/A N/A
7N-5257 125-9750 (2.95275 ± 0.00217 inch) (0.18750 inch) (0.03937 ± 0.00984 inch)
0.15 mm
4.0 mm
(0.00591 inch)
(0.15748 inch)
7E-8779 75.0 ± 0.053 mm and 0.1 mm 1.5 ± 0.5 mm
7N-6983 N/A and Gear 2 is
7N-6982 (2.95275 ± 0.00209 inch) (0.0039 inch) (0.05906 ± 0.01968 inch)
6.35 mm
for the inside
(0.25000 inch)
gear
4.7625 mm
(0.18750 inch)
7E-8777 75.000 ± 0.053 mm 1.5 ± 0.5 mm
7N-6983 N/A N/A and Gear 2 is
8N-1266 (2.95275 ± 0.00209 inch) (0.05906 ± 0.01968 inch)
6.35 mm
(0.25000 inch)
9Y- 55.163 ± 0.041 mm 6 mm 1.0 ± 0.25 mm
7C-7852 N/A N/A
3520 (2.17177 ± 0.00161 inch) (0.23622 inch) (0.03937 ± 0.00984 inch)
2W-7321
105.97 ± 0.01 mm 0.15 mm 0.1 mm 5.0 mm 2.3 ± 0.5 mm
8N-5299 116-1365
116-3242
69.385 ± 0.013 mm 6 mm 1.0 ± 0.25 mm
132-3233 119-3776 N/A N/A
(2.73169 ± 0.00051 inch) (0.23622 inch) (0.03937 ± 0.00984 inch)
69.205 ± 0.013 mm 0.1 mm 0.1 mm 6 mm 1.0 ± 0.25 mm
133-7086 133-7084
112.142 ± 0.01 mm 0.15 mm 0.1 mm 6 mm 2.3 ± 0.5 mm
136-3234 136-3244
105.97 ± 0.01 mm 0.15 mm 0.1 mm 5.0 mm 2.3 ± 0.5 mm
155-2307 116-1365
180-3864 69.95 ± 0.01 mm 8 mm 2.5 ± 0.5 mm
190-6465 N/A N/A
512-3006 (2.75393 ± 0.00039 inch) (0.31496 inch) (0.09843 ± 0.01968 inch)
180-3865 69.95 ± 0.01 mm 8 mm 2.5 ± 0.5 mm
190-6465 N/A N/A
512-3008 (2.75393 ± 0.00039 inch) (0.31496 inch) (0.09843 ± 0.01968 inch)
69.205 ± 0.013 mm 0.1 mm 0.1 mm 6 mm 1.0 ± 0.25 mm
222-3905 133-7084
82.527 ± 0.053 mm 8 mm
286-5303 1W-4738 N/A N/A N/A
(3.2491 ± 0.0021 inch) (0.315 inch)
74.075 ± 0.013 mm 0.1 mm 0.1 mm 5 mm 1.08 ± 0.25 mm
296-5412 296-5413
90.00 ± 0.01 mm 0.15 mm 0.1 mm 10 mm 2.3 ± 0.5 mm
355-5732 140-9597
Table 33
(1)
(2) Maximum Total Indicator Runout (TIR) tolerance read at the gage pins as the gear is rotated in the lathe.
Maximum Total Indicator Runout (TIR) tolerance read on the face of the gear bore as the gear is rotated in the machine.
Note: All the bearing sleeves in Table 33 are Steel Backed Aluminum Bearing Sleeves.
Machining a New Bearing Sleeve

Press in a New Bearing Sleeve
Pressing in a new bearing sleeve. (A) is the fabricated tool used to press in the bearing sleeve accurately.
(A) is an example of a fabricated tool for pressing in bearing sleeves. Notice the lip or edge indicated by the arrows. The lip ensures that the bearing
sleeve is centered in the gear. Since a fabricated tool must be made based on Nominal Machined Bearing Sleeve I.D. and the Bearing Sleeve Depth in
the Gear, a single fabricated tool will not work for all gear assemblies or bearing sleeves. Refer to Table 33 for the Nominal Machined Bearing Sleeve
I.D. and Bearing Sleeve Depth in the Gear Specifications.
Instead of fabricating a tool, you can use a plate or disk to press the bearing sleeve flush to the gear.

After the bearing sleeve is flush with the gear, use a slightly smaller disk that will fit inside the gear to press the bearing sleeve so that it is centered in the
gear.

The two disks used to press in a bearing sleeve. (B) is the larger disk used to press the bearing sleeve flush with the gear. (C) is the smaller disk used to
center the bearing sleeve in the gear.
If the bearing sleeve has an oil groove. Make SURE that the groove is lined up with the oil groove in the gear.
Insert the new bearing sleeve using a hydraulic press. Ensure that the bearing sleeve is centered and square in the gear
bore, unless the assembly print lists a specific depth for the sleeve. Also make sure that the oil passages in the bearing
sleeve are lined with the oil slots in the gear.
Note: Verify the depth of the bore in the gear by looking at the assembly print of the gear.
Aligning the Gear

Locate the gear on the pitch line datum using the following procedure. Locating on the pitch line datum provides the most
consistent and repeatable true position needed for the bearing sleeve bore. The utilization of the pitch line datum minimizes
the compounding errors from multiple machining operations and tolerances.
Note: The locating gage pins for the pitch line must be used (refer to Table 33). Failure to properly align the bearing
sleeve for machining and check required machining specifications, can cause gear train failures.
Each type of gear will require the use of a specific gage pin set. The gage pins are readily available commercially but also
can be made. Care must be taken to precisely machine these gage pins to specification due to the close tolerances of the
gage pin diameters. If these gage pins are to be made, the use of 52100 alloy steel is recommended. These gage pins are
Class ZZ and have an allowed deviation of 0.00508 mm (0.00020 inch), geometry of 0.00254 mm (0.00010 inch), and a
surface texture of 0.2540 µm (10.000 µin) Ra. Each gage pin must be machined for each individual gear set according to
specified dimensions. Refer to Tables 32 and 33 for correct gage pin size.
First rough center the gear on the lathe. If desired, the use of a cone fitting on the tail stock can help with this process.

Hardened gage pins clamped in place under the clamping teeth.
Magnetic gage pins in place around the gears.
To accomplish locating the pitch line datum, use a matched set of hardened gage pins held under the clamping teeth of the
cutting machine. Refer to Illustration 104.
An alternative for using clamped gage pins is to use a matched set of magnetic gage pins next to the jaws to attain a pitch
line. Refer to Illustration 105.
The diameter of the gage pins used will vary with different gear sizes. Refer to Table 33 for gage pin and gear matching
information.
After securing the gear and the correct gage pins, the gear must be aligned for cutting. Take readings on the outer side of
the gage pins with a properly affixed dial indicator, refer to Illustration 106. This measurement will ensure that the gear is
centered in the machine in relation to the pitch line datum of the gear teeth.
Note: If using magnetic gage pins, take care the magnetic draw of the gage pins does not cause an inaccurate reading of
the dial indicator.
Continue to adjust the locating jaws until the reading of the dial indicator is within the tolerance listed in "Max Pitch TIR"
within Table 33.
Check the face perpendicularly with the dial indicator, refer to Table 33 for the minimum specifications.
Adjust the surface of the gear until within "Maximum Gear Perpendicular Runout" specification found within Table 33. The
gear is now centered by the pitch line and perpendicular to the cutting machine. Recheck the gage pins to ensure that the
face adjustment has not compromised the pitch adjustment.
Machining the Gear Bearing Sleeve

Note: If the stub shaft is to be reused, then check the stub shaft prior to machining the bearing sleeve.
The best results for machining the gear bearing sleeve is obtained by using two passes. The first pass will machine the
bearing sleeve to within 0.051 mm (0.002 inch) or less. The second and final pass will machine to final size and final surface
texture. When done correctly, this two-step procedure will leave an acceptable finish requiring no further attention.
Note: The feed and RPM rates for your individual cutting tool, machine, and gear will vary to achieve the best surface
texture. Various cutting tools have been used with different RPM and feed rates to achieve similar results. For example, a
Valenite cutter using a TNMP432 insert used at 1800 RPM and a 0.04572 mm (0.0018 inch) feed rate produced similar
results as a CNMG432MP insert at 850 RPM and a 0.04064 mm (0.0016 inch) feed rate.
Note: The required specifications for cutting aluminum bearing sleeves are in Section "Machining Aluminum Bearing
Sleeves" below.
Using high RPM and slow feed rate will produce the best finish results.
Machining Aluminum Bearing Sleeves

Machining of the aluminum bearing sleeve requires cutting inserts particular to the properties of the metal. Successful trials
were conducted using Kennametal insert number TPGT3252HP KC5410. This insert was used along with Kennametal tool
boring bar E16STFPR3 KWH. The tooling was used at 900 RPM with a feed-rate of .0019. Generously applied WD-40 was
used as a cutting lubricant. The resulting surface texture easily exceeded print specifications noted in the"Specifications"
Table. Consult your tool vendor for other tooling that has the same geometry.
Inspection of Gear Bearing Sleeve After Machining

Checking Bearing Sleeve Diameter

Using a dial bore gauge to measure the bearing sleeve bore size
Critical features such as the bore diameter and surface texture must be checked. The use of proper accuracy of the dial
bore gauge, such as the one shown in Illustration 109, is necessary for inspecting the bearing sleeve diameter. Refer to
Table 33 for diameter specifications. Check the bore diameter at 3-4 different depths to assure there is no taper. Rotate the
gauge inside the bearing sleeve to check that the diameter is not out of round.
Note: The gauge resolution should be 10% of the tolerance window. If tolerance is ± 0.0005 mm (± 0.00002 inch), the
tolerance window is 0.001 mm (0.00004 inch) and the resolution must read at least 0.001 mm (0.00004 inch).
Checking Bearing Sleeve Surface Texture

Typical example of surface texture inspection.
After machining and inspecting the interior diameter of the gear bearing sleeve, it is critical to inspect the surface texture.
Use 448-3698 Profilometer is recommended for measuring the surface texture. Refer to Section "Specifications" for the
finish specifications.
Note: Before measuring the surface texture of the bearing sleeve, make sure the bearing sleeve is clean and free of debris.
Any debris on the surface of the bearing sleeve could make the reading inaccurate.
PIP-10583166
2021/03/28
15:28:23-05:00
i05146489
© 2021 Caterpillar Inc.
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2021/03/09 Reuse and Salvage for Gear Train and Gear Shafts on Engines {0679, 1151, 1162, 1206}

, 1162, 1206} (SEBF9244)

SMCS - 0679,1151,1162,1206 i08377592

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

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

Your safety is involved.

Canceled Part Numbers and Replaced Part Numbers

Service Letters and Technical Information Bulletins

Media Number Title

Tooling and Equipment

To avoid component damage, follow the recommended

Required Tooling and Equipment

Part Number Description

Standardized Parts Marking Procedure

Prepare the Area for Inspection

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

Personal injury can result from air pressure.

Personal injury can result without following proper procedure.

Remove all removable plugs before cleaning.

Use appropriate thread taps to chase all threaded holes.

Nomenclature for Front and Rear Gear Train

3500 Rear Gear Train

C175 Front Gear Train

C175 Rear Gear Train

Visual Inspection of Gears

Machining - Finish a surface with a machine.

Pitting - Small holes from corrosion and wear

Polished - Surface that is smooth and shiny as a result of wear

Nomenclature of Gear Tooth

Strong light source

Use the gear again.

Use the gear again.

The areas indicate a typical area of normal wear.

Use the gear again.

The areas of wear show some light corrosion.

Use the gear again.

Oil can cause discoloration on sections of some teeth.

Use the gear again.

Do not use the gear again.

Do not use the gear again.

Excessive wear has destroyed the profiles of the teeth.

Do not use the gear again.

The amount of wear is different on each tooth.

Do not use the gear again.

Use the gear again.

Pitting at the pitch line of each tooth

Do not use the gear again.

Pitting in the radius of each gear tooth

Do not use the gear again.

Examples of heavy pitting

Do not use the gear again.

Examples of heavy pitting and excessive wear

Do not use the gear again.

Light pitting that has been polished.

Use the gear again.

Use the gear again.

Use the gear again.

Typical marks from machining

Use the gear again.

Typical horizontal and vertical machining marks

Use the gear again.