1/30/24, 3:40 PM SIS 2.

Reuse and Salvage for Gear Train and Gear Shafts on 3500 Series and C175 Engines {0679, 1151, 1162, 1206} (SEBF9244-25)

SMCS - 0679, 1151, 1162, 1206 i10081106

Caterpillar Products
All Cat Engines

Revision History:
Table 1
PIP
202 1046 -
Revision Summary of Changes in SEBF9244
Corrected Column (A) for part numbers, 259-6312, 416-8057, and 331-3656 in Table 7.
25 Added 1 part number to Table 7

4 4
Added 370-0014 to Table 18.

12: 01/3 666

/
24 Corrected a part numbers in Tables 7, 33, and34 .
Added idler gears, 443-6069 and 443-9634, to Table 33.
23

4
Added auxiliary shafts, 525-2221 and 455-5305, to Table 7

SEB 0:07+ 0
22 Added new serial number prefixes.
21 Corrected callouts in Illustration 73

© 2 F924 03:00
This document is the result of the combination of M0068228, SEBF8045, SEBF8188, SEBF8377, SEBF9191, SEBF9192, and SEBF9316.

© 2024 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes

Cat 4 C 0 2 4
therein without permission may be violation of intellectual property law.

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

e r
Con illa terpi a
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage

p
information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information
that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not

fide r: llar
included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

ntia Inc
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.
l Ye
l lo
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS web)

Canceled Part Numbers and Replaced Part Numbers w

interface.

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System
website 2.0 (SIS web 2.0) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced
parts.

Important Safety Information

Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An
accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this
instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot

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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. Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair
procedures that are used. Ensure that the product will not be damaged or made unsafe by any 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”. Refer to
Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

Illustration 2 g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

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

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

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

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

Summary
This guideline provides the procedures necessary to determine the reusability of gears and gear shafts for engines. Life will vary depending on application,
load, lubrication, and environment.

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.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. Parts are expected to reach the next
Planned Component Rebuild (PCR) if the parts meet the specifications within this guideline and are intended for similar applications. Use this guideline to
determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have
caused the original failure.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to
condemn a part from reuse.

References
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Note: Refer to the appropriate Remove and Install (R&I), Disassembly and Assembly (D&A), and Operation and Maintenance Manual (OMM) for the part
or machine of focus before initiating this inspection or procedure.

Table 2

References

Media Number Publication Type & Title

"Why Reuse and Salvage Parts"
Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Cat Inspect https://catinspectweb.cat.com/
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Reuse and Salvage Guidelines
SEBF8148
, "General Salvage and Reconditioning Techniques"
Reuse and Salvage Guidelines
SEBF8187
, "Standardized Parts Marking Procedures".
Applied Failure Analysis
SEBF9066
, "Guideline for Examining Failed Parts".
Special Instruction
SEHS9826
, "Ordering "Series B" Replacement Cylinder Blocks for 3500 Series Engines"

Service Advisories, Service Letters, and Technical Service Bulletins

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

Tooling and Equipment

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

Table 3

Required Tooling and Equipment

Part Number Description

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
634-9137 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

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607-8035 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)
FT-3302 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)

Measurement Requirements

NOTICE
Precise measurements shall be made when the
component and measurement equipment are at 20 °C
(68 °F). Measurements shall be made after both the
component and measurement equipment have had
sufficient time to soak at 20 °C (68 °F). This will ensure
that both the surface and core of the material is at the
same temperature.

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Preparation Recommendations
Reference: SEBF9066 Applied 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.

Note: Clean exterior housing of the gear train and gear shafts prior to disassembly to minimize cross-contamination.

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.

Illustration 3 g01201262
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.

Refer to , SEBF8148 Reuse and Salvage Guidelines , "General Salvage and Reconditioning Techniques" for available Crack Detection Methods.

Polishing
Note: Do not use polishing stone on shaft journals.

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Illustration 4 g03885189
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.

Illustration 5 g03885193
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 5.

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

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Illustration 6 g06289580
(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

Illustration 7 g06177134
(1) Ring
(2) Camshaft Drive Gear
(3) Idler Gear Assembly
(4) Bearing Sleeve
(5) Thrust Washer
(6) Bolt
(7) Cluster Gear Shaft

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(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

Illustration 8 g06312890
(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

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PIP
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4
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© 2 F924 03:00
0
Cat 4 C2 4
Illustration 9
Accessory Drive Gear (6) and Idler Gear (4).
e
Con rpilla aterpi
g06312895

llar
(A) High-Speed Drive Gear

fide r:
(B) Medium Speed Drive Gear
(C) Low Speed Drive Gear

Inc
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

ntia
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 l Ye

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Illustration 10 g06289603
(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

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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

Illustration 11 g01625725
(1) End
(2) Tip
(3) Edge
(4) Face of the Tooth
(5) Pitch line
(6) Radius
(7) Profile

Illustration 12 g01625728
Teeth on a new gear

Effects of Wear

Illustration 13 g01625742
The polished areas are examples of normal wear.

Use the gear again.

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Illustration 14 g01625753

The gears that are shown in Illustration 13 and Illustration 14 show some loss of material from the teeth in addition to areas that are polished.

Use the gear again.

Illustration 15 g01625757

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.

Illustration 16 g01625766

The areas of wear show some light corrosion.

Use the gear again.

Illustration 17 g01625767

Oil can cause discoloration on sections of some teeth.

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Use the gear again.

Illustration 18 g01625789

The surfaces of the gear teeth are not polished. Not polished gear teeth surfaces are an indication of excessive wear. Also see Illustration 19.

Do not use the gear again.

Illustration 19 g01625797

The faces of the gear teeth are not polished. Not polished gear teeth faces are an indication of excessive wear.

Do not use the gear again.

Illustration 20 g01625800

Excessive wear has destroyed the profiles of the teeth.

Do not use the gear again.

Illustration 21 g01625801

The amount of wear is different on each tooth.

Do not use the gear again.

Effects of Pitting

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Illustration 22 g01625805
Pitting on the ends of the teeth

Use the gear again.

Illustration 23 g01625808

Pitting at the pitch line of each tooth

Do not use the gear again.

Illustration 24 g01625809

Pitting in the radius of each gear tooth

Do not use the gear again.

Illustration 25 g01625811

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Illustration 26 g01625812

Illustration 27 g01625814

Examples of heavy pitting

Do not use the gear again.

Illustration 28 g01625821

Illustration 29 g01625822

Examples of heavy pitting and excessive wear

Do not use the gear again.

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Illustration 30 g01625823

Light pitting that has been polished.

Use the gear again.

Effects of Machining

Illustration 31 g01625844

Illustration 32 g01625845
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.

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Illustration 33 g01625872
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.

Illustration 34 g01625880

Typical marks from machining

Use the gear again.

Note: Illustration 34 is not a gear. However, these marks appear similar on all gears.

Illustration 35 g01625892

Illustration 36 g01625893

Typical horizontal and vertical machining marks

Use the gear again.

Nicks, Cracks, and Other Damage to the Surface

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Illustration 37 g01626112
4
SEB 0:07+ 0
© 2 F924 03:00
Small nicks on one edge and the tip of a tooth

Use the gear again.

0 4
Use the gear again after the sharp edges of the nick are smoothed with a 6V-2010 Polishing Stone.

Cat 4 C2
e
Con rpilla aterpi
fide r: llar
ntia Inc
l Ye .
llow
Illustration 38 g01626115

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.

Illustration 39 g01626116

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.

Illustration 40 g01626122

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A crack in the end of a tooth

Do not use the gear again.

Illustration 41 g01626125

A deep gouge across the center of the tooth face.

Do not use the gear again.

Illustration 42 g01626129

Raised ridges along the faces of the teeth

Do not use the gear again.

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 33 for machining lips.

Illustration 43 g01626173

This gear is a typical example of severe plastic yielding. The lips are not of even height.

Do not use the gear again.

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Illustration 44 g01626179

This gear contains severe plastic yielding. The lips are not of even height.

Do not use the gear again.

Scoring

Illustration 45 g01626182
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.

Inspection for the 255-4445 Fuel Pump Drive Gear

Illustration 46 g07507051
(1) Gear
(2) Hub

1. Perform gear inspection, Refer to table 4 for wear limit specifications. If the gear does not pass inspection, replace the gear.

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Illustration 47 g07493017
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.

Illustration 48 g06266456

Illustration 49 g06026327

3. Fasten tooling FT-3302 with two bolts and nuts.

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Illustration 50 g07495860
The drawing in Illustration 50 shows updated Tooling.
4. Place the plate from tooling FT-3302 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. Place the gear in the center of the plate so the gear teeth engage the pins and will not rotate. Then clamp the gear to
the plate.

Illustration 51 g07496626

Illustration 52 g03891400

5. Place the dial indicator in position (Z), 90° to Tooling FT-3302.

6. Attach torque wrench to Tooling FT-3302. Apply 35 N·m (26 lb ft). Observe Total Indicated Runout (TIR) reading and record when 35 N·m (26 lb ft) is
reached. The coupling has 0.045 mm (0.0018 inch) of allowable total axial movement at 35 N·m (26 lb ft).

7. Perform this procedure 3 times and use the average of the three tests to determine reusability. Zero the dial indicator before each test. Use Table 4 to
determine Total Indicated Runout (TIR). If the gear meets the TIR specification, the gear should be replaced. The gear is not serviceable.
Table 4
Rotational Movement Test

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Description Results
Test 1 __________
Test 2 (+) __________
Test 3 (+)__________
Sum of the results of all three tests (= x) __________
(x / 3 =) __________

Specification
Divided by 3
0.045 mm (0.0018 inch)
at
35 N·m (26 lb ft)
8. Remove the bar from Tooling FT-3302, but leave the plate attached.

Illustration 53 g07493029

9. Place the dial indicator perpendicular to, and contacting, the hub face. Zero dial indicator.

Illustration 54 g07495840

10. Place thumbs on gear and firmly grasp Inside Diameter (I.D.) of the hub. With thumbs pushing down on coupling, firmly pull up the hub with the fingers
and record the highest reading observed on the dial indicator. Use caution not to bump or move indicator. The gear has 0.60 mm (0.0236 inch) of
allowable total axial movement.
Perform this procedure 3 times and use the average of the three tests to determine reusability. Zero the dial indicator before each test. Use Table 5 to
determine amount of axial travel. If the gear does not meet the axial travel specification, the gear should be replaced. The gear is not serviceable.

Table 5
Axial Movement Test
Description Results
Test 1 __________
Test 2 (+) __________
Test 3 (+)__________
Sum of the results of all three tests (= x) __________
(x / 3 =) __________
Divided by 3
Specification
0.60 mm (0.0236 inch)

Wear Limit for High Pressure Fuel Pump Gear

Table 6
Hub Motion Relative to the Gear
Rotational Axial
0.045 mm (0.0018 inch) at 35 Nm 0.60 mm (0.02362 inch)

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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.

Illustration 55 g06323759
Visual reference example of C175 and 3500 auxiliary shafts

Illustration 56 g06323789
Visual reference example of C175 oil & water pump shafts

Illustration 57 g06324088
Visual reference example of C175 idler shafts

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Illustration 58 g06332367
Visual reference example of 3500 PTO shafts

Illustration 59 g06324150
Visual reference example of C175 PTO shafts

Illustration 60 g03327456
Check the splines of the gear shaft for wear steps.

Examples of Acceptable Wear on Gear Shafts

Illustration 61 g07275439
Inspect the interior (1) and exterior (2) mating surfaces for acceptable and unacceptable damage as shown in the following sections.

Nicks and Dings

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Most nicks and dings are acceptable as long as the shaft meets minimum surface texture and other reuse specifications.

Illustration 62 g03326412
Remove any raised edges around dings with a 6V-2010 Polishing Stone (Fine). Up to 3 dings are allowable..

Illustration 63 g03421276
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.

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PIP
-
202 1046
12: 4 / 0 4 666
4 1 / 3
Illustration 64
SEB :07+ 0
g03327542
Use Again if Shaft Meets Minimum Specifications.
0
© 2 F924 03:00
Cat 024 C 4
e r
Con illa terpi
p a
fide r: llar
ntia Inc
l Ye .
Illustration 65 g03327546
Use Again if Shaft Meets Minimum Specifications.

Other Acceptable Damage Types

llow

Illustration 66 g03327468
Minor damage on the wear sleeve surface. Use Again if Shaft Meets Minimum Specifications.

Illustration 67 g03327484
Rough surface on a non-critical area of Idler Shaft. Use Again if Shaft Meets Minimum Specifications.

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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 55 - 59. Shafts with small nicks
are acceptable, and the shaft must meet minimum specifications and there are no raised material surrounding the nick.

Illustration 68 g03326367
This shaft has excessive amounts of corrosion in a critical area (A) and cannot be reused. Do Not Use Again.

Illustration 69 g06322894
This shaft has excessive amounts of corrosion in a critical area (B) and cannot be reused. Do Not Use Again.

Illustration 70 g03327549
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

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Illustration 71 g06332338

Table 7

Auxiliary, Oil & Water Pump Shaft Diameters and Surface Textures
B E
A C D
Part Surface Texture of Surface Texture of
Diameter of Shorter End of Minimum Length for Diameter of Longer End of
Number Shorter End of Longer End of
Shaft Surface Texture of (E) Shaft
Shaft Shaft
74.9 ± 0.015 mm Ra 0.80 µm 74.9 ± 0.015 mm Ra 0.80 µm
246-6691 40 mm (1.575 inch)
(2.949 ± 0.0006 inch) (31.49606 µinch) (2.949 ± 0.0006 inch) (31.49606 µinch)
74.9 ± 0.015 mm Ra 0.80 µm 93.9 ± 0.015 mm Ra 0.80 µm
251-5516 40 mm (1.575 inch)
(2.949 ± 0.0006 inch) (31.49606 µinch) (3.696 ± 0.0006 inch) (31.49606 µinch)
259-6312 74.9 + 0.015 / - 0.020 mm Ra 0.80 µm 74.9 + 0.015 / - 0.020 mm Ra 0.80 µm
40 mm (1.575 inch)
416-8057 (2.949 +0.0006 / -0.0008 inch) (31.49606 µinch) (2.949 +0.0006 / -0.0008 inch) (31.49606 µinch)
74.90 ± 0.015 mm Ra 0.80 µm 74.9 ± 0.015 mm Ra 0.80 µm
331-3656 40 mm (1.575 inch)
(2.9488 ± 0.0006 inch) (31.49606 µinch) (2.949 ± 0.0006 inch) (31.49606 µinch)
Maximum
74.90 ± 0.015 mm 74.9 ± 0.015 mm Ra 0.80 µm
367-0069 Ra 3.50 µm 40 mm (1.575 inch)
(2.9488 ± 0.0006 inch) (2.949 ± 0.0006 inch) (31.49606 µinch)
(137.80 µinch)
30.022 ± 0.008 mm Ra 1.6 µm 58.13 ± 0.125 mm 25.409 ± 0.004 mm Ra 0.4 µm
371-6781
(1.1820 ± 0.0003 inch) (62.99213 µinch) (2.289 ± 0.0050 inch) (1.0004 ± 0.0002 inch) (15.75 µinch)
74.90 ± 0.015 mm Ra 0.80 µm 74.90 ± 0.015 mm Ra 0.80 µm
455-5305 40 mm (1.575 inch)
(2.9488 ± 0.0006 inch) (31.49606 µinch) (2.9488 ± 0.0006 inch) (31.49606 µinch)
452-7876 74.90 ± 0.015 mm Ra 0.80 µm 74.90 ± 0.015 mm Ra 0.80 µm
40 mm (1.575 inch)
525-2221 (2.9488 ± 0.0006 inch) (31.49606 µinch) (2.9488 ± 0.0006 inch) (31.49606 µinch)

Specifications for Idler Shafts

Illustration 72 g06332334

Table 8

Idler Shaft Diameters and Surface Textures

Part Number F G H J
Diameter of Larger End of Surface Texture of Larger Diameter of Smaller End of Surface Texture of

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Shaft End of Shaft Shaft Smaller End of Shaft
129.86 ± 0.05 mm 89.88 ± 0.02 mm 0.80 µm (31.49606 µinch)
7C-3260 5.5 µm (216.5354µinch) Ra
(5.11259 ± 0.00197 inch) (3.53858 ± 0.00079 inch) Ra
88.00 ± 0.50 mm 69.142 ± 0.008 mm
218-7270 — 0.50 µm (19.6850 µinch)
(3.4646 ± 0.0197 inch) (2.7221 ± 0.0003 inch)
129.86 ± 0.05 mm 105.88 ± 0.02 mm 0.80 µm (31.49606 µinch)
250-9947 5.5 µm (216.5354µinch) Ra
(5.11259 ± 0.00197 inch) (4.16850 ± 0.00079 inch) Ra
129.86 ± 0.05 mm 89.88 ± 0.02 mm 0.80 µm (31.49606 µinch)
277-6911 5.5 µm (216.5354µinch) Ra
(5.11259 ± 0.00197 inch) (3.53858 ± 0.00079 inch) Ra
129.86 ± 0.05 mm 105.88 ± 0.02 mm 0.80 µm (31.49606 µinch)
282-8915 5.5 µm (216.5354µinch) Ra
(5.11259 ± 0.00197 inch) (4.16850 ± 0.00079 inch) Ra
329-8192 161.73 ± 0.05 mm < 3.5 µm 119.814 ± 0.012 mm 0.80 µm (31.49606 µinch)
430-8141 (6.36731 ± 0.00197 inch) (< 137.7953 µinch) Ra (4.71708 ± 0.00047 inch) Ra
329-8190
161.73 ± 0.05 mm < 3.5 µm 119.814 ± 0.012 mm 0.80 µm (31.49606 µinch)
419-1361
(6.36731 ± 0.00197 inch) (< 137.7953 µinch) Ra (4.71708 ± 0.00047 inch) Ra
430-8140
560-9446 587-3650 67.0 ± 0.1 mm 19.990 ± 0.01 mm
— 1.6 µm (62.99213 µinch)
592-1779 599-2438 (2.64 ± 0.004 inch) (0.78701 ± 0.00039 inch)

Specifications for PTO Shafts

Illustration 73 g07526446

Illustration 74 g06332700

Table 9

PTO Shaft Diameters and Surface Textures

Surface
Diameter Surface Texture Diameter Diameter Surface Texture Diameter
Part Texture
Number
K L M P R S
N
1.6 µm 0.2 µm < 3.5 µm
4P-3743 59.946 ± 0.013 mm 63.42 ± 0.013 mm 95.0 ± 0.015 mm 63.42 ± 0.013
(62.992 µinch) (7.8740 µinch) (< 137.7953 µinch)
121-5796 (2.3601 ± 0.0005 inch) (2.4969 ± 0.0005 inch) (3.7402 ± 0.0006 inch) (2.4969 ± 0.0005
Ra Ra Ra

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35 µm 0.2 µm < 3.5 µm

57.897 ± 0.05 mm 63.43 ± 0.01 mm 95.0 ± 0.015 mm 63.43 ± 0.01 m
289-6329 (1377.953 µinch) (7.8740 µinch) (< 137.7953 µinch)
(2.2794 ± 0.002 inch) (2.4972 ± 0.0004 inch) (3.7402 ± 0.0006 inch) (2.4972 ± 0.0004
Ra Ra Ra
35 µm 0.2 µm < 3.5 µm
57.897 ± 0.05 mm 63.43 ± 0.01 mm 101.5 ± 0.015 mm 63.43 ± 0.01 m
290-1630 (1377.953 µinch) (7.8740 µinch) (< 137.7953 µinch)
(2.2794 ± 0.002 inch) (2.4972 ± 0.0004 inch) (3.9961 ± 0.0007 inch) (2.4972 ± 0.0004
Ra Ra Ra
1.6 µm 0.2 µm < 3.5 µm
188-4783 59.946 ± 0.013 mm 63.42 ± 0.013 mm 95.0 ± 0.015 mm 63.42 ± 0.013
(62.9921 µinch) (7.8740 µinch) (< 137.7953 µinch)
315-3096 (2.3601 ± 0.0005 inch) (2.4969 ± 0.0005 inch) (3.7402 ± 0.0006 inch) (2.4969 ± 0.0005
Ra Ra Ra

Sleeve Installation and Machining Procedure

Fuel Pump Adapter Assembly

Illustration 75 g06289620
Note: When you are installing the bearing sleeve, the hole in the bearing sleeve must be aligned with oil passage (B).

Table 10

Pump Adapter Assembly

Specifications for Bearing Sleeve Inside Diameter (ID) after Installation
Pump Adapter Assembly Bearing Sleeve Diameter
Part Number Part Number A
328-1980 328-1981 93.990 ± 0.01 mm (3.7004 ± 0.0004 inch)
291-1998
354-1562 318-4810 94.056 mm (3.7030 inch)
485-0316

Engine Oil Pump Adapter Assembly

Illustration 76 g06289621
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).

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Table 11

Engine Oil Pump Adapter Assembly

Specifications for Bearing Sleeve Inside Diameter (ID) after Installation
Engine Oil Pump Adapter Assembly Bearing Sleeve Diameter
Part Number Part Number C
247-3417 127-5400 75.00 ± 0.055 mm (2.9528 ± 0.0022 inch)
328-1972 328-1971 74.975 ± 0.01 mm (2.9518 ± 0.0004 inch)
348-7075 348-7074 75.023 mm (2.9537 inch)

Front Adapter Assemblies

Illustration 77 g06289632
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).

Table 12

Front Adapter Assembly

Specifications for Bearing Sleeve Inside Diameter (ID) after Installation
Front Adapter Assembly Bearing Sleeve Diameter
Part Number Part Number F
248-7582 127-5400 75.0 ± 0.055 mm (2.9528 ± 0.0022 inch)
328-1973 328-1971 74.975 ± 0.01 mm (2.9518 ± 0.0004 inch)
348-7076 348-7074 75.035 mm (2.9541 inch)

Low, Medium, and High-Speed Idler Gears

Illustration 78 g06312920

Table 13

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Low, Medium, and High-Speed Idler Gear Assemblies

Specifications for Bearing Sleeve Inside Diameter (ID) after Installation
Diameter Installation Depth Surface Texture
Part Number
I J K
250-9949
105.970 ± 0.01 mm (4.17204 ± 0.00039 inch) 2.3 ± 0.5 mm (0.0905 ± 0.0197 inch) 0.80 µm (31.4961 µinch) Ra
250-9950
307-2402 89.964 ± 0.01 mm (3.5419 ± 0.0004 inch) 2.3 ± 0.5 mm (0.0905 ± 0.0197 inch) 0.80 µm (31.4961 µinch) Ra
312-1676 105.98 ± 0.01 mm (4.1724 ± 0.0004 inch) 2.3 ± 0.5 mm (0.0905 ± 0.0197 inch) 0.80 µm (31.49606 µinch) Ra
312-1677 105.98 ± 0.01 mm (4.1724 ± 0.0004 inch) 2.3 ± 0.5 mm (0.0905 ± 0.0197 inch) 0.80 µm (31.49606 µinch) Ra

Idler (Cluster) Gear and Shaft

Illustration 79 g06332306

Table 14

254-5886 Idler (Cluster) Gear with 254-5887 Bearing Sleeve

Location Description Dimension

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 (31.4961 µinch) Ra

Table 15

500-3454 and 588-4925 Idler (Cluster) Gear with 493-2533 Bearing Sleeve

Location Description Dimension

A Machined Diameter of Bearing Sleeve 38.015 ± 0.015 mm (1.4967 ± 0.0006 inch)
B Installation Depth 0.5 ± 0.3 mm (0.02 ± 0.01 inch)
C Surface Texture 0.60 µm (23.62 µinch) Ra

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Illustration 80 g06332307
Example of cluster gear shaft

Table 16

327-0811 and 328-7113 Cluster Gear Shaft

Location Description Dimension

D Shaft Diameter 74.97 ± 0.01 mm (2.9516 ± 0.0004 inch)
E Surface Texture 0.13 µm (5.1181 µinch) Ra

Illustration 81 g06312800
Example of idler and cluster gear

Table 17

Idler and Cluster Gear Specifications

Machined Diameter of Bearing Sleeve
Part Surface Texture Installation Depth Diameter of Original Gear Bore
After Installation
Number F G J
H
0.80 µm 1 ± 0.5 mm 128.009 ± 0.013 mm
254-5919 120.051 mm (4.7264 inch)
(31.4961 µinch) Ra (0.0394 ± 0.0197 inch) (5.0397 ± 0.0005 inch)
0.80 µm 1 ± 0.5 mm 128.009 ± 0.013 mm
275-6559 120.052 mm (4.7265 inch)
(31.4961 µinch) Ra (0.0394 ± 0.0197 inch) (5.0397 ± 0.0005 inch)
0.80 µm 1 ± 0.5 mm 128.009 ± 0.013 mm
478-5468 119.93 ± 0.01 mm (4.7216 ± 0.0004 inch)
(31.4961 µinch) Ra (0.0394 ± 0.0197 inch) (5.0397 ± 0.0005 inch)
0.80 µm 1 ± 0.5 mm 128.009 ± 0.013 mm
478-5469 119.93 ± 0.01 mm (4.7216 ± 0.0004 inch)
(31.4961 µinch) Ra (0.0394 ± 0.0197 inch) (5.0397 ± 0.0005 inch)

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PIP
202 1046-
4
12: 01/3 666
/ 4
4
SEB 0:07+ 0
© 2 F924 03:00
Cat 024 C 4
Illustration 82
e r
Con illa terpip
Example of auxiliary drive gear a
g06312830

Table 18

fide r: llar
Inc
Auxiliary Drive Gear Specifications

Part Number
K
ntia
Diameter of Original Gear Bore

.
245-1357
l Ye
95.05 ± 0.025 mm (3.74212 ± 0.00098 inch)

l
273-3816 101.551 ± 0.025 mm (3.99806 ± 0.00098 inch)
370-0014
l o 3500 Engines
74.980 ± 0.025 mm (2.95196 ± 0.00098 inch)

Salvage Procedures for Front and Rear Gear Train onw

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.

Table 19

Part Numbers for the Bearing Sleeve

Former Bearing Sleeve Description New Bearing Sleeve

7N-5243 High-Speed Idler Gear Assembly 140-9597
8N-5301 Low Speed Idler Gear Assembly 116-1365
7N-5244 Adapter Assembly 127-5400

Affected Engines

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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 20. All the attachments that are low speed drives that were made
afterOctober 1996have the new bearing sleeves on the front idler gear assemblies.

Table 20

Effective Serial Numbers for Low Speed Idler Gear Assemblies

Model 3508 3512 3516

Industrial (S/N: 68Z)S/N:68Z874-UP N/A S/N:71Z324-UP
Marine S/N:69Z717-UP N/A S/N:72Z518-UP
Generator Set S/N:70Z952-UP N/A S/N:73Z768-UP
S/N:1313-UP S/N:4KC567-UP S/N:3RC1113-UP
Gas (Right Side) S/N:2JF325-UP S/N:5JD22-UP S/N:8LD28-UP
S/N:9TG56-UP S/N:7NJ108-UP S/N:4EK510-UP
S/N:2JF344-UP S/N:4KC640-UP S/N:3RC1201-UP
Gas (Left Side) S/N:9TG123-UP S/N:5JD30-UP S/N:8LD38-UP
N/A S/N:7NJ221-UP S/N:4EK1096-UP

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 21.

Table 21

Effective Serial Numbers for High-Speed Adapter Assemblies

Model 3508 3512 3516

Industrial S/N:95Y1019-UP S/N:49Y836-UP S/N:27Z776-UP
S/N:96Y1731-UP S/N:50Y1519-UP S/N:29Z1235-UP
S/N:7SM85-UP S/N:4TN101-UP S/N:4MJ177-UP
Marine
S/N:2BM123-UP S/N:7HM176-UP S/N:8KN156-UP
N/A S/N:8EM264-UP S/N:8CN146-UP
Marine Auxiliary S/N:3DM94-UP N/A S/N:9AN122-UP
S/N:23Z6906-UP S/N:24Z8021-UP S/N:25Z5597-UP
S/N:6PN302-UP S/N:8RM216-UP S/N:4XF678-UP
Generator Set S/N:4GM224-UP S/N:6WN142-UP S/N:5SJ547-UP
N/A N/A S/N:7RN473-UP
N/A N/A S/N:6HN162-UP
Locomotive S/N:6TJ14-UP S/N:2WK76-UP S/N:9KF104-UP
Vehicular S/N:97Y718-UP S/N:51Y761-UP S/N:28Z649-UP
Petroleum N/A S/N:1LM142-UP N/A
S/N:2JF349-UP S/N:4KC646-UP S/N:3RC1228-UP
Gas S/N:9TG148-UP S/N:7NJ303-UP S/N:4EK1352-UP
N/A N/A S/N:5PN35-UP
D11N
776B S/N:99W3520-UP N/A N/A
777B
D11R
5130
S/N:7YG2092-UP N/A N/A
776C
777C
D11R S/N:2GR744-UP N/A N/A
992G

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776D
777D
789
793 N/A N/A S/N:54Z1170-UP
994
789B
793B N/A N/A S/N:2PK1455-UP
5230
793C
N/A N/A S/N:7TR402-UP
994G

Table 22

Front Gear Train

Option 1 Option 2 Option 3

Idler Gear Assembly
Idler Gear Assembly(1) High Strength Bearing Sleeve Medium Strength Bearing Sleeve
2W-0548 153-1243 116-1365 8N-5301
2W-7321 116-3242 116-1365 8N-5301
7E-0274 144-8263 140-9597 7N-5243
111-8145 144-8263 140-9597 7N-5243
116-3242 116-3242 116-1365 8N-5301
144-8263 144-8263 140-9597 7N-5243
420-2042 420-2042 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
(1) New idler gear assemblies come with bearing sleeves installed and machined.
(2) New adapter assemblies come with bearing sleeves installed.

Table 22 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 22.

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 22 shows the required parts for each
particular option for rework.

Option 1 - New Assembly

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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 "Sleeve Installation and Machining Procedure" Section 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 remove and install procedures from the appropriate Service Manual. The same removal procedure for the
former bearing sleeves is used for new bearings.

The specifications in Table 23 are for installation and the machining of the inside diameter of new bearing sleeves.

1. When an idler gear assembly (4) is reconditioned, bearing sleeve (3) is installed into the gear to depth (C).

2. Machine by honing the inside diameter to dimension (A)

Illustration 83 g01509263
The illustration shows items for the bearing sleeve in the idler gear assembly. Refer to Table 23 for identification of the items and dimensions.

Table 23

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.
(1) High-speed idler gears.
(2) The surface texture of the inside diameter must be 0.8 micro meter (31.50 micro inch).

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(3) Low speed idler gears.

3500 Rear Gear Train

Table 24

3500 Rear Gear Train

New Part Numbers

Quantity Former Part Number Description Replace As Needed Option 1 Option 2 Option 3 Option 4
1 7E-5324 Ring 7E-5324 N/A N/A N/A N/A
4W-4793 (2)
7E-3897 (1)
153-1243 420-2042 N/A
7E-3897 7E-3897(1) N/A N/A N/A
2
100-6518 Camshaft Drive Gear N/A 100-6518 N/A N/A N/A
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
2 115-5281 Idler Gear Assembly (3)
N/A 115-5281 N/A N/A 121-4749
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 115-5283 115-5283 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 4P-5437 4P-5437 N/A N/A
1 Shaft of the Cluster Gear(5)(6) N/A
4P-5456 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

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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)
107-2477 N/A N/A N/A
1 Cluster Gear Assembly(5)(6) N/A
4P-5458 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
(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 100-6518 Camshaft Drive Gear must be
used in all 3516 S/N:4MJ34-UP Marine Engines unless 8 pitch gears are used.
(2) Canceled
(3) 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 guideline.
(4) This part is not Canceled.
(5) 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" section in this Guideline.
(6) Order the part number that is specific to the engine application.

During rebuild, refer to Table 24 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 Group has been developed. The new rear gear group is a direct replacement for the former 4W-5906 Rear Gear Group.
The new gear group is now effective with all the 3516 marine engines. The serial number 4MJ34-UP 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.

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Illustration 84 g06177130
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 steel backed aluminum bearing sleeves to steel backed bronze
bearing sleeves. 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 steel backed bronze bearing sleeve 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 25.

The second stage incorporated the introduction of the new steel backed bronze bearing sleeves, the change in diameter and number of oil feed holes to
the cluster and idler shafts, and the 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 26
lists the engines that are affected by these changes. Engines that are first listed in the Table 26 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 27 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 28.

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Next, the interference fit between the idler gear and bearing sleeve was increased. Table 29 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 30.

Note: Not all serial numbers are listed in Table 30. All engines that were manufactured after June 1995contain cluster gears with an increased interference
fit.

Table 25

Effective Serial Numbers for Case Carburized Gears in Rear Gear Trains (Camshaft Drive)

Model 3508 3512 3516

Industrial N/A S/N:65Z715-UP S/N:71Z297-UP
Marine N/A S/N:66Z423-UP S/N:72Z415-UP
Generator Set (low speed) N/A S/N:67Z794-UP S/N:73Z405-UP
D11N
776B S/N:99W1942-UP N/A N/A
777B
789 N/A S/N:54Z661-UP N/A

Table 26

Effective Serial Numbers for Changes to the Cluster and Shaft of the Idler Bearing Sleeve

Model 3508 3512 3516

Industrial S/N:95Y791-UP S/N:49Y606-UP S/N:27Z693-UP
Industrial S/N:68Z776-UP S/N:65Z724-UP S/N:71Z302-UP
S/N:29Z967-UP
Marine S/N:96Y1147-UP S/N:50Y948-UP S/N:4MJ34-UP
S/N:5MJ33-UP
Marine S/N:69Z562-UP S/N:66Z434-UP S/N:72Z427-UP
S/N:23Z3671-UP S/N:24Z3920-UP S/N:25Z226-UP
Generator Set
S/N:1ZF593-UP S/N:3YF604-UP S/N:4XF382-UP
Generator Set (low speed) S/N:70Z775-UP N/A S/N:73Z463-UP
Locomotive N/A N/A S/N:9KF56-UP
Vehicular S/N:97Y673-UP S/N:51Y629-UP S/N:28Z625-UP
D11N
776B S/N:99W2752-UP N/A N/A
777B
785 N/A S/N:96Z740-UP N/A
789 N/A S/N:54Z719-UP N/A

Table 27

Effective Serial Numbers for Idler Shafts with Three Bolt Hole Patterns

Model 3508 3512 3516

Industrial S/N:95Y942-UP S/N:49Y741-UP S/N:27Z759-UP
Industrial S/N:68Z838-UP S/N:65Z805-UP S/N:71Z318-UP
S/N:29Z1120-UP
Marine S/N:96Y1485-UP S/N:50Y1317-UP S/N:4MJ162-UP
S/N:5MJ33-UP
Marine S/N:69Z664-UP S/N:66Z579-UP S/N:72Z427-UP
S/N:25Z4283-UP
Generator Set S/N:23Z5701-UP S/N:24Z6028-UP S/N:4XF572-UP
S/N:5SJ289-UP
Generator Set (low speed) S/N:70Z887-UP S/N:67Z1185-UP S/N:73Z682-UP
Locomotive S/N:6TJ12-UP S/N:2WK40-UP S/N:9KF80-UP
Vehicular S/N:97Y688-UP S/N:51Y731-UP S/N:28Z635-UP

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Petroleum N/A S/N:1LM48-UP N/A

S/N:2JF302-UP S/N:4KC557-UP S/N:3RC1072-UP
Gas
S/N:9TG27-UP S/N:5JD19-UP S/N:4EK374-UP
D11N
776B S/N:99W3447-UP N/A N/A
777B
D11R
5130
S/N:7YG959-UP N/A N/A
776C
777C
785 N/A S/N:96Z912-UP N/A
785B N/A N/A S/N:4WJ535-UP
789
793 N/A S/N:54Z1069-UP N/A
994
789B
793B N/A S/N:2PK679-UP N/A
5230

Table 28

Effective Serial Numbers for the Introduction of 8 Pitch Gears

Model 3508 3512 3516

Marine N/A N/A S/N:4MJ150-UP
S/N:5SJ162-UP
Generator Set N/A N/A
S/N:4XF460-UP

Table 29

Effective Serial Numbers for 125-9751 Bearing Sleeve

Model 3508 3512 3516

Industrial S/N:95Y968-UP S/N:49Y760-UP S/N:27Z762-UP
Industrial S/N:68Z843-UP S/N:65Z831-UP S/N:71Z318-UP
S/N:29Z1168-UP
Marine S/N:96Y1563-UP S/N:50Y1383-UP
S/N:5MJ33-UP
Marine S/N:69Z685-UP S/N:66Z613-UP S/N:72Z481-UP
S/N:23Z6191-UP S/N:25Z4726-UP
Generator Set S/N:24Z6689-UP
S/N:8TL3-UP S/N:4XF606-UP
Generator Set (low speed) S/N:70Z925-UP S/N:67Z1286-UP S/N:73Z701-UP
S/N:9KF103-UP
Locomotive S/N:6TJ14-UP N/A
S/N:5PN35-UP
Vehicular S/N:97Y697-UP S/N:51Y740-UP S/N:28Z637-UP
Petroleum N/A S/N:1LM67-UP N/A
S/N:2JF330-UP S/N:4KC593-UP S/N:3RC1126-UP
Gas S/N:9TG67-UP S/N:5JD23-UP S/N:4EK600-UP
S/N:4WD13-UP S/N:7NJ133-UP S/N:8LD28-UP
D11N
776B S/N:99W3487-UP N/A N/A
777B
D11R
5130
S/N:7YG1438-UP N/A N/A
776C
777C
785 N/A S/N:96Z913-UP N/A
785B N/A S/N:4WJ643-UP N/A

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789
793 N/A N/A S/N:54Z1117-UP
994

PIP
789B
793B N/A N/A S/N:2PK906-UP

Table 30
5230
-
202 1046
Effective Serial Numbers for the Increased

12: 4 / 0 4 666
1
Interference Fit Cluster Gear.

4 / 3
SEB :07+ 0
0
Model 3508 3512 3516
Marine N/A N/A S/N:8KN68-UP
S/N:5SJ353-UP
Generator Set N/A N/A

© 2 F924 03:00
S/N:4XF593-UP
Locomotive N/A N/A S/N:5PN35-UP
S/N:5JD20-UP S/N:4EK371-UP

0 4
Gas N/A
S/N:7NJ73-UP S/N:8LD28-UP
785B N/A S/N:4WJ545-UP

Cat 4 C2 N/A

e
789B

Con rpilla aterpi

793B N/A N/A S/N:2PK680-UP
5230

fide r:
Reconditioning the Components of the Rear Gear Train
llar
ntia Inc
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.

l Ye
2. Use the original gears with new bronze bearing sleeves and shafts. .
llow
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 24 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

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"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

Illustration 85 g02515196
The illustration shows the tools that are required for the rework procedure. Refer to Table 31 for the part numbers and the description.

Table 31

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)
28 1 4C-9995(2) Drill Bushing 13.49 mm (0.531 inch)
29 1 4C-9994 (2)
Drill Bushing 12.70 mm (0.500 inch)
30 1 9U-5033 (2)
Core Drill, four fluted 13.49 mm (0.531 inch)
(1) Bolts that are used for installing the original idler shaft
(2) This tool is included in the 4C-9991 Tool Group for Retrofitting of Idler Shaft.

Procedure

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Illustration 86 g02515277
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)
(29) Drill Bushing 12.70 mm (0.500 inch)

1. Install bearing sleeve (28) and (29) into guide plate (24).

Illustration 87 g02515296
The illustration shows the installed guide plate (24).
(22) Bolt Bolt, 1/2-13 thd., 69.9 mm (2.75 inch)
(24) Guide Plate
(28) Drill Bushing 13.49 mm (0.531 inch)
(29) Drill Bushing 12.70 mm (0.500 inch)

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).

Illustration 88 g01477933
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

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when the drill contacts the bottom of the hole.
4. Clean the debris from the drilled hole.

Illustration 89 g02515336
Installing the guide bushing for tapping
(26) Drill Bushing 16.13 mm (0.635 inch) (pilot for 15.88 mm (0.625 inch) tap)
(28) Drill Bushing 13.49 mm (0.531 inch)

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.

Illustration 90 g02515359
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/

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Illustration 91 g02515376
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.
(27) Drill Bushing 15.88 mm (0.625 inch)
(28) Drill Bushing 13.49 mm (0.531 inch)
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.

Illustration 92 g06177158
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 ( 4P-5090 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.

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Illustration 93 g01477940
The new idler shaft is shown on the left. The old idler shaft is shown on the right.

Illustration 94 g01477942
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).

Illustration 95 g06177163
The illustration shows an assembly of a balancer gear. Refer to Table 32 for reference dimensions.

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Illustration 96 g06177165
The illustration shows an idler gear assembly. Refer to Table 32 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.

Table 32

Specifications for Installing and Machining Bearing Sleeves

Location Dimension
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.
(1) The surface texture of the inside diameter must be 0.8 µm (32 µinch).
(2) 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 steel backed bronze 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 33 and 34). 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 33 and 34.

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 33 and 34.

Table 33

Idler Gear and Shaft Specifications for Steel Backed Bronze Bearing Sleeve
Gear
Bearing Nominal Machined Bearing Pitchline Total Max Gear Face
Assembly Gear Gage Pin Bearing Sleeve Depth in
Sleeve Part Sleeve Inside Diameter Indicated Runout Total Indicated
Part Diameter the Gear
Number (ID) (TIR) (1) Runout (TIR)(2)
Number
4P-3130
7E-7194 9Y-1539 150.002 ± 0.02 mm 10 mm 3 ± 0.5 mm
N/A N/A
130-5478 432-4362 (5.90558 ± 0.00079 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
75.06 ± 0.01 mm 0.15 mm 0.05 mm 1.5 ± 0.5 mm
4P-5457 4P-5460 the Gear 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
75.06 ± 0.01 mm 0.15 mm 0.05 mm 1.5 ± 0.5 mm
4P-5458 4P-5460 the Gear 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)

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5 mm (0.19685 inch)
75.06 ± 0.01 mm 0.15 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
4P-5459 4P-5438
(2.95511 ± 0.00039 inch) (0.00591 inch) (0.00197 inch) pin size is 6.35 mm (0.05906 ± 0.01968 inch)
(0.25000 inch)
6 mm (0.23622 inch)
75.06 ± 0.01 mm 0.15 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
101-1363 101-1372
(2.95511 ± 0.00039 inch) (0.00591 inch) (0.00197 inch) pin size is 5 mm (0.05906 ± 0.01968 inch)
(0.19685 inch)
101-1374 81.06 ± 0.01 mm 0.15 mm 0.1 mm 1 ± 0.25 mm
101-1364 6 mm (0.23622 inch)
125-9751 (3.19133 ± 0.00039 inch) (0.00591 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)
6 mm (0.23622 inch)
75.06 ± 0.01 mm 0.15 mm and the Gear 2-gage 1.5 ± 0.5 mm
101-1377 4P-5460 N/A
(2.95511 ± 0.00039 inch) (0.00591 inch) pin size is 5 mm (0.05906 ± 0.01968 inch)
(0.19685 inch)
0.15 mm
6 mm (0.23622 inch)
(0.00591 inch) and
101-1381 75.06 ± 0.01 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
101-1372 0.1 mm
114-3372 (2.95511 ± 0.00039 inch) (0.00197 inch) pin size is 5 mm (0.05906 ± 0.01968 inch)
(0.0039 inch) for the
(0.19685 inch)
inside gear
0.15 mm
5 mm (0.19685 inch)
(0.00591 inch) and
75.06 ± 0.01 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
107-2477 4P-5438 0.1 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) pin size is 6.35 mm (0.05906 ± 0.01968 inch)
(0.0039 inch) for the
(0.25000 inch)
inside gear
101-1374 81.06 ± 0.01 mm 0.12 mm 0.05 mm 1 ± 0.25 mm
112-1554 4 mm (0.15748 inch)
125-9751 (3.19133 ± 0.00039 inch) (0.00472 inch) (0.00197 inch) (0.03937 ± 0.00984 inch)
0.15 mm
5 mm (0.19685 inch)
(0.00591 inch) and
75.06 ± 0.01 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
115-5277 115-5279 0.1 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) pin size is 6.35 mm (0.05906 ± 0.01968 inch)
(0.0039 inch) for the
(0.25000 inch)
inside gear
81.06 ± 0.01 mm 0.12 mm 0.1 mm 1.00 ± 0.25 mm
127-4628 125-9751 8 mm (0.31496 inch)
(3.19133 ± 0.00039 inch) (0.00472 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)
0.15 mm
8 mm (0.31496 inch)
(0.00591 inch) and
75.06 ± 0.01 mm 0.1 mm and the Gear 2-gage 1.5 ± 0.5 mm
136-3277 101-1372 0.1 mm
(2.95511 ± 0.00039 inch) (0.0039 inch) pin size is 12 mm (0.05906 ± 0.01968 inch)
(0.0039 inch) for the
(0.47244 inch)
inside gear
0.15 mm
(0.00591 inch) and 5 mm (0.19685 inch)
128-2661 (3)
63.566 ± 0.013 mm 0.1 mm 2.8 ± 0.5 mm
149-9107 0.1 mm and Gear 2 is 6 mm
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) (0.11024 ± 0.01968 inch)
(0.0039 inch) for the (0.23622 inch)
inside gear
0.15 mm 4.7625 mm
(0.00591 inch) and (0.18750 inch) and
63.566 ± 0.013 mm 0.1 mm 0.38 ± 0.25 mm
151-2946 4N-0343 0.1 mm the Gear 2-gage pin
(2.50259 ± 0.00051 inch) (0.0039 inch) (0.01496 ± 0.00984 inch)
(0.0039 inch) for the size is 5 mm
inside gear (0.19685 inch)
101-1374 81.06 ± 0.01 mm 0.12 mm 0.1 mm 1 ± 0.25 mm
175-5197 6 mm (0.23622 inch)
125-9751 (3.19133 ± 0.00039 inch) (0.00472 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)
0.15 mm
6 mm (0.23622 inch)
(0.00591 inch) and
75.06 ± 0.01 mm 0.1 mm and the Gear 2-gage 1.5 ± 0.5 mm
175-5200 101-1372 0.1 mm
(2.95511 ± 0.00039 inch) (0.0039 inch) pin size is 5 mm (0.05906 ± 0.01968 inch)
(0.0039 inch) for the
(0.19685 inch)
inside gear
0.15 mm
8 mm (0.31496 inch)
185-1495 (0.00591 inch) and
71.035 ± 0.013 mm 0.1 mm and the Gear 2-gage 2.5 ± 0.5 mm
331-6185 224-9664 0.1 mm
(2.79665 ± 0.00051 inch) (0.0039 inch) pin size is 10 mm (0.09843 ± 0.01968 inch)
610-3009 (0.0039 inch) for the
(0.39370 inch)
inside gear
71.035 ± 0.013 mm 0.1 mm 0.1 mm 2.6 ± 0.5 mm
185-1497 224-9664 8 mm (0.31496 inch)
(2.79665 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.10236 ± 0.01968 inch)
0.15 mm
5 mm (0.19685 inch)
(0.00591 inch) and
128-2661 (3)
63.566 ± 0.013 mm 0.1 mm and Gear 2-gage pin 2.8 ± 0.5 mm
187-8979 0.1 mm
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) size is 6 mm (0.11024 ± 0.01968 inch)
(0.0039 inch) for the
(0.23622 inch)
inside gear
200-2454 128-2661(3) 63.566 ± 0.013 mm 0.15 mm 0.1 mm 5 mm (0.19685 inch) 2.8 ± 0.5 mm
131-7123 (2.50259 ± 0.00051 inch) (0.00591 inch) and (0.0039 inch) and Gear 2 is 6 mm (0.11024 ± 0.01968 inch)
0.1 mm (0.23622 inch)

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PIP
(0.0039 inch) for the
inside gear

202 -1046
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm Center the bearing sleeve
206-4225 209-8621
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) in the gear
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm Center the bearing sleeve
207-8211 209-8621

4 4
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) in the gear

12: / 01 666 0.15 mm

(0.00591 inch) and
8 mm (0.31496 inch)

/
88.09 ± 0.013 mm 0.1 mm and the Gear 2-gage 3.2 ± 0.5 mm

3
226-6036 226-6052 0.1 mm

4
(3.46810 ± 0.00051 inch) (0.0039 inch) pin size is 10 mm (0.12598 ± 0.01968 inch)

SEB :07+ 0
0
(0.0039 inch) for the
(0.39370 inch)
inside gear
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm 3 ± 0.5 mm
228-5814 209-8621
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) (0.11811 ± 0.01968 inch)

© 2 F924 03:00
0.15 mm
8 mm (0.31496 inch)
(0.00591 inch) and
71.035 ± 0.013 mm 0.1 mm and the Gear 2-gage 2.6 ± 0.5 mm
230-6202 224-9664 0.1 mm
(2.79665 ± 0.00051 inch) (0.0039 inch) pin size is 4 mm (0.10236 ± 0.01968 inch)

0 4
(0.0039 inch) for the

2
(0.15748 inch)
inside gear

250-9949 116-1365
Cat 4 C
105.970 ± 0.01 mm
— —
10 mm 2.30 ± 0.50 mm

e
(4.1720 ± 0.0004 inch) (0.39370 inch) (0.09055 ± 0.01969 inch)

250-9950 116-1365
r
Con illa terpi
p
105.970 ± 0.01 mm
a
(4.1720 ± 0.0004 inch)
— — 8 mm (0.31496 inch)
2.30 ± 0.50 mm
(0.09055 ± 0.01969 inch)

llar
0.15 mm

fide r:
8 mm (0.31496 inch)
(0.00591 inch) and
75.06 ± 0.01 mm 0.1 mm and the Gear 2 gage 2 ± 0.5 mm
254-5886 254-5887 0.1 mm
(2.95511 ± 0.00039 inch) (0.0039 inch) pins size is 10 mm (0.07874 ± 0.01968 inch)

Inc
(0.0039 inch) for the

ntia
(0.39370 inch)
inside gear

.
0.08 mm 10 mm 1.5 ± 0.5 mm

l Ye
254-5919 146-7395 120.051 mm (4.72641 inch) —
(0.0032 inch) Both Gears (0.0591 ± 0.0197 inch)
0.15 mm

llow
6 mm (0.23622 inch)
(0.00591 inch) and
75.06 ± 0.01 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
261-3133 101-1372 0.1 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) pin size is 5 mm (0.05906 ± 0.01968 inch)
(0.0039 inch) for the
(0.19685 inch)
inside gear
101-1374 81.06 ± 0.01 mm 0.12 mm 0.05 mm 1 ± 0.25 mm
261-3137 6 mm (0.23622 inch)
125-9751 (3.19133 ± 0.00039 inch) (0.00472 inch) (0.00197 inch) (0.03937 ± 0.00984 inch)
0.15 mm
8 mm (0.31496 inch)
(0.00591 inch) and
88.09 ± 0.013 mm 0.1 mm and the Gear 2-gage 3.2 ± 0.5 mm
261-3443 226-6052 0.1 mm
(3.46810 ± 0.00051 inch) (0.0039 inch) pin size is 10 mm (0.12598 ± 0.01968 inch)
(0.0039 inch) for the
(0.39370 inch)
inside gear
88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm 3 ± 0.5 mm
261-3445 209-8621
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) (0.11811 ± 0.01968 inch)
0.15 mm 4.7625 mm
(0.00591 inch) and (0.18750 inch) and
63.566 ± 0.013 mm 0.1 mm 0.38 ± 0.25 mm
271-5656 128-2661(3) 0.1 mm the Gear 2-gage pin
(2.50259 ± 0.00051 inch) (0.0039 inch) (0.01496 ± 0.00984 inch)
(0.0039 inch) for the size is 5 mm
inside gear (0.19685 inch)
0.08 mm 10 mm 1.5 ± 0.5 mm
275-6559 146-7395 120.052 mm (4.72645 inch) —
(0.0032 inch) (0.39370 inch) (0.05906 ± 0.01968 inch)
0.15 mm 4.763 mm
(0.00591 inch) and (0.18752 inch) and
128-2661(3) 63.566 ± 0.013 mm 0.1 mm 0.38 ± 0.25 mm
300-5575 0.1 mm the Gear 2-gage pin
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) (0.01496 ± 0.00984 inch)
(0.0039 inch) for the size is 5 mm
inside 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
(3.54192 ± 0.00039 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) (0.09055 ± 0.01968 inch)
6 mm (0.23622 inch)
75.06 ± 0.01 mm 0.15 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
310-3177 101-1372
(2.95511 ± 0.00039 inch) (0.00591 inch) (0.00197 inch) pin size is 5 mm (0.05906 ± 0.01968 inch)
(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
(4.17243 ± 0.00039 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) (0.09055 ± 0.01968 inch)
105.98 ± 0.01 mm 0.1 mm 0.1 mm 2.3 ± 0.5 mm
312-1677 312-1678 8 mm (0.31496 inch)
(4.17243 ± 0.00039 inch) (0.0039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)
251-2317 88.09 ± 0.013 mm 0.1 mm 0.1 mm 10 mm 3.00 ± 0.5 mm
209-8621
320-6198 (3.46810 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) (0.39370 inch) (0.11811 ± 0.01968 inch)

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6 mm (0.23622 inch)
128-2661(3) 63.566 ± 0.013 mm 0.1 mm 0.1 mm and the Gear 2-gage 2.8 ± 0.5 mm
352-9728
131-7123 (2.5026 ± 0.0005 inch) (0.0039 inch) (0.0039 inch) pin size is 6 mm (0.11024 ± 0.01968 inch)
(0.23622 inch)
55.663 ± 0.013 mm 0.05 mm 1.50 ± 0.50 mm
360-0444 7C-7852 — 5 mm (0.19685 inch)
(2.19155 ± 0.0005 inch) (0.00197 inch) (0.0591 ± 0.0197 inch)
69.205 ± 0.013 mm 0.05 mm 1.00 ± 0.30 mm
361-5600 133-7084 — 5 mm (0.19685 inch)
(2.72460 ± 0.00051 inch) (0.00197 inch) (0.0394 ± 0.0118 inch)
6 mm (0.23622 inch)
63.566 ± 0.013 mm 0.1 mm 0.1 mm and the Gear 2-gage Center the bearing sleeve
361-8233 128-2661(3)
(2.50259 ± 0.00051 inch) (0.0039 inch) (0.0039 inch) pin size is 6 mm in the gear
(0.23622 inch)
51.41 ± 0.013 mm 0.05 mm 1.50 ± 0.50 mm
361-8236 101-8468 — 6 mm (0.23622 inch)
(2.0240 ± 0.0005 inch) (0.00197 inch) (0.0591 ± 0.0197 inch)
51.41 ± 0.013 mm 0.05 mm 1.50 ± 0.50 mm
361-8238 130-4698 — 6 mm (0.23622 inch)
(2.0240 ± 0.0005 inch) (0.00197 inch) (0.0591 ± 0.0197 inch)
101-1374 81.06 ± 0.01 mm 0.15 mm 0.1 mm 1 ± 0.25 mm
369-9356 6 mm (0.23622 inch)
125-9751 (3.19133 ± 0.00039 inch) (0.00591 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)
0.15 mm
6 mm (0.23622 inch)
(0.00591 inch) and
75.06 ± 0.01 mm 0.05 mm and the Gear 2-gage 1.5 ± 0.5 mm
369-9357 101-1372 0.1 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) pin size is 5 mm (0.05906 ± 0.01968 inch)
(0.0039 inch) for the
(0.19685 inch)
inside gear
10 mm
(0.39370 inch) and
75.06 ± 0.01 mm 0.1 mm 0.1 mm 1.5 ± 0.5 mm
386-2938 101-1372 the Gear 2-gage pin
(2.95511 ± 0.00039 inch) (0.0039 inch) (0.0039 inch) (0.05906 ± 0.01968 inch)
size is 8 mm
(0.31496 inch)
81.06 ± 0.01 mm 0.12 mm 0.1 mm 1.00 ± 0.25 mm
386-2948 125-9751 8 mm (0.31496 inch)
(3.1913 ± 0.0004 inch) (0.00472 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)
50.857 ± 0.013 mm 0.05 mm 1.5 ± 0.5 mm
417-4615 417-4616 N/A 6 mm (0.23622 inch)
(2.00224 ± 0.00051 inch) (0.00197 inch) (0.05906 ± 0.01968 inch)
50.857 ± 0.013 mm 0.05 mm 1.5 ± 0.5 mm
417-4617 417-4618 N/A 6 mm (0.23622 inch)
(2.00224 ± 0.00051 inch) (0.00197 inch) (0.05906 ± 0.01968 inch)
55.114 ± 0.013 mm 0.05 mm 1.00 ± 0.250 mm
417-9605 417-9606 N/A 5 mm (0.1969 inch)
(2.1698 ± 0.0005 inch) (0.00197 inch) (0.0394 ± 0.0098 inch)
81.06 ± 0.01 mm 0.12 mm 0.1 mm 1.00 ± 0.250 mm
443-6069 125-9751 8 mm (0.31496 inch)
(3.1913 ± 0.0004 inch) (0.0047 inch) (0.00394 inch) (0.0394 ± 0.0098 inch)
Small Gear
75.06 ± 0.01 mm 0.1 mm 1.5 ± 0.5 mm
443-9634 101-1372 0.1 mm 8 mm (0.31496 inch)
(2.95511 ± 0.00039 inch) (0.00394 inch) (0.05906 ± 0.01968 inch)
(0.00394 inch)
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)
(1) Maximum Total Indicator Runout (TIR) tolerance read at the gage pins as the gear is rotated in the lathe.
(2) Maximum Total Indicator Runout (TIR) tolerance read on the face of the gear bore as the gear is rotated in the machine.
(3) 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 33 are Steel Backed Bronze Bearing Sleeves.

Table 34

Idler Gear and Shaft Specifications for Steel Backed Aluminum Bearing Sleeves
Gear Bearing
Pitchline Total Max Gear Face
Assembly Sleeves Nominal Bearing Sleeve Gear Gage Pin Bearing Sleeve Depth in
Indicated Runout Total Indicated
Part Part Inside Diameter (ID) Diameter the Gear
(TIR)(1) Runout (TIR)(2)
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
7N-5257 7N-5258 75.000 ± 0.055 mm 4.7625 mm 1.0 ± 0.25 mm
N/A N/A
7E-3894 125-9750 (2.95275 ± 0.00217 inch) (0.18750 inch) (0.03937 ± 0.00984 inch)
0.15 mm 4.0 mm
7N-6982 75.0 ± 0.053 mm (0.00591 inch) and (0.15748 inch) and 1.5 ± 0.5 mm
7N-6983 N/A
7E-8779 (2.95275 ± 0.00209 inch) 0.1 mm (0.0039 inch) Gear 2 is 6.35 mm (0.05906 ± 0.01968 inch)
for the inside gear (0.25000 inch)

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4.7625 mm
8N-1266 75.000 ± 0.053 mm (0.18750 inch) and 1.5 ± 0.5 mm
7N-6983 N/A N/A
7E-8777 (2.95275 ± 0.00209 inch) Gear 2 is 6.35 mm (0.05906 ± 0.01968 inch)
(0.25000 inch)
55.163 ± 0.041 mm 6 mm 1.0 ± 0.25 mm
9Y-3520 7C-7852 N/A N/A
(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
(4.17204 ± 0.00039 inch) (0.00591 inch) (0.0039 inch) (0.19685 inch) (0.09055 ± 0.01968 inch)
116-3242
119-3777
69.385 ± 0.013 mm 6 mm 1.0 ± 0.25 mm
128-0419 119-3776 N/A N/A
(2.73169 ± 0.00051 inch) (0.23622 inch) (0.03937 ± 0.00984 inch)
132-3233
69.205 ± 0.013 mm 0.1 mm 0.1 mm 6 mm 1.0 ± 0.25 mm
133-7086 133-7084
(2.72460 ± 0.00051 inch) (0.00394 inch) (0.00394 inch) (0.23622 inch) (0.03937 ± 0.00984 inch)
112.142 ± 0.01 mm 0.15 mm 0.1 mm 6 mm 2.3 ± 0.5 mm
136-3234 136-3244
(4.41503 ± 0.00039 inch) (0.00591 inch) (0.0039 inch) (0.23622 inch) (0.09055 ± 0.01968 inch)
105.97 ± 0.01 mm 0.15 mm 0.1 mm 5.0 mm 2.3 ± 0.5 mm
155-2307 116-1365
(4.17204 ± 0.00039 inch) (0.00591 inch) (0.0039 inch) (0.19685 inch) (0.09055 ± 0.01968 inch)
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
1N-3833 69.95 ± 0.01 mm 8 mm 2.5 ± 0.5 mm
190-6465 N/A N/A
7E-8173 (2.75393 ± 0.00039 inch) (0.31496 inch) (0.09843 ± 0.01968 inch)
512-3006
69.205 ± 0.013 mm 0.1 mm 0.1 mm 6 mm 1.0 ± 0.25 mm
222-3905 133-7084
(2.72460 ± 0.00051 inch) (0.00394 inch) (0.00394 inch) (0.23622 inch) (0.03937 ± 0.00984 inch)
0.25 mm 0.1 mm 10 mm 1.5 ± 0.5 mm
243-3008 243-3007 137.91 mm (5.42952 inch)
(0.00984 inch) (0.0039 inch) (0.39370 inch) (0.05906 ± 0.01968 inch)
82.527 ± 0.053 mm
286-5303 1W-4738 N/A N/A 8 mm (0.315 inch) N/A
(3.2491 ± 0.0021 inch)
74.075 ± 0.013 mm 0.1 mm 0.1 mm 1.08 ± 0.25 mm
296-5412 296-5413 5 mm (0.1969 inch)
(2.91633 ± 0.00051 inch) (0.00394 inch) (0.00394 inch) (0.04252 ± 0.00984 inch)
90.00 ± 0.01 mm 0.15 mm 0.1 mm 2.3 ± 0.5 mm
355-5732 140-9597 10 mm (0.394 inch)
(3.543 ± 0.0004 inch) (0.00591 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)
69.205 ± 0.013 mm 0.05 mm 1.00 ± 0.250 mm
361-5600 133-7084 N/A 5 mm (0.1969 inch)
(2.7246 ± 0.0005 inch) (0.0020 inch) (3) (0.0394 ± 0.0098 inch)
(1) Maximum Total Indicator Runout (TIR) tolerance read at the gage pins as the gear is rotated in the lathe.
(2) Maximum Total Indicator Runout (TIR) tolerance read on the face of the gear bore as the gear is rotated in the machine.
(3) Bore face TIR

Note: All the bearing sleeves in Table 34 are Steel Backed Aluminum Bearing Sleeves.

Machining a New Bearing Sleeve

Press in a New Bearing Sleeve

Illustration 97 g03309216
Pressing in a new bearing sleeve. (A) is the fabricated tool used to press in the bearing sleeve accurately.

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Illustration 98 g03383297
(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. A
fabricated tool must be made based on 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 Tables 33 and 34 for the Bearing Sleeve I.D. and Bearing Sleeve Depth in the Gear Specifications.

Illustration 99 g03382785
Instead of fabricating a tool, you can use a plate or disk to press the bearing sleeve flush to the gear.

Illustration 100 g03383265

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.

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Illustration 101 g03383270

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.

Illustration 102 g03383282

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 34). 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 33 and 34 for correct gage pin size.

Illustration 103 g03307317

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.

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Illustration 104 g03306717

Hardened gage pins clamped in place under the clamping teeth.

Illustration 105 g03307436

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 34 for gage pin and gear matching information.

Illustration 106 g03307017

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.

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Continue to adjust the locating jaws until the reading of the dial indicator is within the tolerance listed in "Max Pitch TIR" within Table 34.

Illustration 107 g03307542

Check the face perpendicularly with the dial indicator, refer to Table 34 for the minimum specifications.

Adjust the surface of the gear until within "Maximum Gear Perpendicular Runout" specification found within Table 34. 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.

Illustration 108 g03784239

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

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Checking Bearing Sleeve Diameter

Illustration 109 g03310276

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 34 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

Illustration 110 g03308640

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, ensure the bearing sleeve is clean and free of debris. Any debris on the surface of the
bearing sleeve could make the reading inaccurate.

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