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Welcome: r120hxt
Product: GEN SET ENGINE
Model: G3516B GEN SET ENGINE CEY
Configuration: G3516B 60 Hz Generator Set Engine CEY00001-UP

Reuse And Salvage Guidelines

Reuse and Salvage for Gear Train and Gear Shafts on Engines {0679, 1151, 1162, 1206}
Media Number -SEBF9244-10 Publication Date -26/01/2015 Date Updated -07/03/2019
Caterpillar: Confidential Yellow

i07704230

Reuse and Salvage for Gear Train and Gear Shafts on Engines {0679, 1151, 1162, 1206}
SMCS - 0679; 1151; 1162; 1206

Caterpillar Products
All Cat Engines

Introduction
Table 1
Revision Summary of Changes in SEBF9244

10 Added New SN Prefixes.

08–09 Corrected callouts.- Added C175 aux and PTO shafts.

Combined information from M0068228, SEBF8045, SEBF8188, SEBF8377, SEBF9191, SEBF9192, SEBF9316, added 29 part numbers and repaired 14 pixelated
07
illustrations.

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission
may be violation of intellectual property law.

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

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Cat dealers
and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and
advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest
technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Important Safety Information

Illustration 1 g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be
avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded,
bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings
in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar
is used, then ensure that the procedure is safe for you and other people. Ensure that the product will not be damaged or the product will not be made unsafe by the operation,
lubrication, maintenance, or the repair procedures that are used.

Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on r120hxt

this product, until you have read and understood the operation, Caterpillar: Confidential Yellow
 lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other
persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

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
The illustrations in this guideline show specific examples of reusability for gears and gear shafts for engines. Normally, the reusability of the gears is determined from the condition
of the gear teeth. Damage in other areas on the gear is not common and easily identified.

If a gear is within the specifications in this guideline, the gear can be expected to give normal performance until the next overhaul when the gear is used again in the same
application. Correct all conditions that damaged the gear.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR
will provide the current part numbers for replaced parts.

Service Letters and Technical Information Bulletins

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

References
Table 2
References
Media Number Title

SEBF8187 Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

SEBF9066 Applied Failure Analysis, "Guideline for Examining Failed Parts".

SEHS9826 Special Instruction, "Ordering "Series B" Replacement Cylinder Blocks for 3500 Series Engines"

Tooling and Equipment

NOTICE
Failure to follow the recommended procedure or the specified tooling
that is required for the procedure could result in damage to
components.
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To avoid component damage, follow the recommended procedure using Caterpillar: Confidential Yellow
the recommended tools.
 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

6V-7059 Micrometer

8S-2257 Eye Loupe

8T-5096 Dial Indicator Group

9A-1593 Surface Texture Comparison Gauge

222-3062 Air Drill

Pocket Microscope
262-8390
40X

303-9339 Lint Free Shop Towels

Micrometer Extensions,
Internal
385-9422
50 - 609 mm
(2 - 24 inch)

Digital Caliper
423-4373 0.0 - 203.2 mm
(0.00 - 8.00 inch)

Micrometer, External
431-4150
25 mm (1 inch)

448-3698 Profilometer
Micrometer, Inside
473-8688 2.00 - 12.00 inch
or
473-8689 Micrometer, Inside
50 - 300 mm

Micrometer, Outside
473-8690
0.00 - 4.00 inch

Outside Electronic Micrometer Set

473-8691
2-6 inch

Micrometer, Outside
473-8692
152.4 - 304.8 mm (6.00 - 12.00 inch)

Micrometer, Inside
474-3709 (8.00 - 32.00 inch)
or
474-3710 Micrometer, Inside
200 - 800 mm

549-3500 Precision Gage Pin Set

Precision Gage Pins
549-3505 4.000 mm
(0.15748 inch)

Precision Gage Pins

549-3506 5.000 mm
(0.19685 inch)
Precision Gage Pins
549-3508 6.000 mm
(0.23622 inch)

Precision Gage Pins

549-3510 8.000 mm
(0.31496 inch) r120hxt
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 549-3512 Precision Gage Pins
10.000 mm
(0.39370 inch)

FT3302 TIR Tooling

- Carbide tipped drill bit 5.94 mm (0.234 inch)

- Cobalt drill bit 5.94 mm (0.2339 inch)
Precision Gage Pins
- 4.7625 mm
(0.18750 inch)

Precision Gage Pins

- 6.350 mm
(0.25000 inch)

Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is
important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part. Use a metal marking pen to mark the code onto the component.

NOTICE
Do not use numbering stamp punches to mark internal components.
The impact from striking the stamp will cause an abnormal stress riser.
The added stress riser may cause premature part failure.

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

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

Example 1

Illustration 4 g03856853
Typical Example

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

Example 2

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Illustration 5 g03856857
Typical Example

Illustration 5 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice.
The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 5. In this example, the gear has a total of 22,000 hours.

Measurement Requirements

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

Prepare the Area for Inspection

Reference: , SEBF9066Applied Failure Analysis, "Guideline for Examining Failed Parts".

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and warnings on

the cleaner solvent container before using.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.

The first step of visual examination is to prepare the surface of the part for inspection. Even thin layers of oil, grease, or other materials may hide important facts. Generally,
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 6 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. r120hxt

Caterpillar: Confidential Yellow
 Use a fast drying, mild solvent to soak and/or rinse parts clean.

Make sure that you remove all debris, paint, and oil but Do Not wipe, scrub, or scratch to clean part.

When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all
lifting devices must be inspected before use.

Do not wipe parts with a shop towel to dry, air dry, blow with dry compressed air, or blot dry with a paper towel.

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

Illustration 7 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 8 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 8.

NOTICE
If the tooth has a raised metal area, remove only the raised portion. Do
not try to remove pitting or any other recessed surface damage. Do not
use a grinder or power polisher, use only a hand-held stone. Using
power tools to remove damage can also remove the case hardened
surface of the gear, causing eventual failure.

Nomenclature for Front and Rear Gear Train

3500 Front Gear Train

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Illustration 9 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 10 g06177134
(1) Ring
(2) Camshaft Drive Gear
(3) Idler Gear Assembly
(4) Bearing Sleeve
(5) Thrust Washer
(6) Bolt
(7) Cluster Gear Shaft
(8) Idler Gear Shaft
(9) Bolt
(10) Bolt
(11) Bearing Sleeve
(12) Bolt r120hxt
(13) Hard Washer Caterpillar: Confidential Yellow
(14) Cluster Gear Assembly
(15) Thrust Plate
(16) Plate
(17) Bolt
(18) Bolt
(19) Crankshaft Gear

C175 Front Gear Train

Illustration 11 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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Illustration 12 g06312895
Accessory Drive Gear (6) and Idler Gear (4).
(A) High-Speed Drive Gear
(B) Medium Speed Drive Gear
(C) Low Speed Drive Gear

TheC175 Engines use either a low, medium, or high-speed accessory drive. The HIGH speed models use a 53 Tooth Idler Gear (5) and a 61 Tooth Accessory Drive Gear (7). The
MEDIUM speed models use a 57 Tooth Idler Gear (5) and a 53 tooth Accessory Drive Gear (7). The LOW speed models use a 64 Tooth Idler Gear (5) and a 41 tooth Accessory
Drive Gear (7). Make sure to check your gears to be sure that the correct dimensions are used.

C175 Rear Gear Train

Illustration 13 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

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 14 g01625725
(1) End
(2) Tip r120hxt
(3) Edge Caterpillar: Confidential Yellow
(4) Face of the Tooth
(5) Pitch line
(6) Radius
(7) Profile

Illustration 15 g01625728
Teeth on a new gear

Effects of Wear

Illustration 16 g01625742

The polished areas are examples of normal wear.

Use the gear again.

Illustration 17 g01625753

The gears that are shown in Illustration 16 and Illustration 17 show some loss of material from the teeth in addition to areas that are polished.

Use the gear again.

Illustration 18 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.

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Illustration 19 g01625766

The areas of wear show some light corrosion.

Use the gear again.

Illustration 20 g01625767

Oil can cause discoloration on sections of some teeth.

Use the gear again.

Illustration 21 g01625789

The surfaces of the gear teeth are not polished. Not polished gear teeth surfaces are an indication of excessive wear. Also see Illustration 22.

Do not use the gear again.

Illustration 22 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.

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Illustration 23 g01625800

Excessive wear has destroyed the profiles of the teeth.

Do not use the gear again.

Illustration 24 g01625801

The amount of wear is different on each tooth.

Do not use the gear again.

Effects of Pitting

Illustration 25 g01625805

Pitting on the ends of the teeth

Use the gear again.

Illustration 26 g01625808

Pitting at the pitch line of each tooth

Do not use the gear again.

Illustration 27 g01625809

Pitting in the radius of each gear tooth

Do not use the gear again.

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Illustration 28 g01625811

Illustration 29 g01625812

Illustration 30 g01625814

Examples of heavy pitting

Do not use the gear again.

Illustration 31 g01625821

Illustration 32 g01625822

Examples of heavy pitting and excessive wear

Do not use the gear again.

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Illustration 33 g01625823

Light pitting that has been polished.

Use the gear again.

Effects of Machining

Illustration 34 g01625844

Illustration 35 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.

Illustration 36 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.

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Illustration 37 g01625880

Typical marks from machining

Use the gear again.

Note: Illustration 37 is not a gear. However, these marks appear similar on all gears.

Illustration 38 g01625892

Illustration 39 g01625893

Typical horizontal and vertical machining marks

Use the gear again.

Nicks, Cracks, and Other Damage to the Surface

Illustration 40 g01626112

Small nicks on one edge and the tip of a tooth

Use the gear again.

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

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Illustration 41 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 42 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 43 g01626122

A crack in the end of a tooth

Do not use the gear again.

Illustration 44 g01626125

A deep gouge across the center of the tooth face.

Do not use the gear again.

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Illustration 45 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 36 for machining lips.

Illustration 46 g01626173

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

Do not use the gear again.

Illustration 47 g01626179

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

Do not use the gear again.

Scoring

Illustration 48 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.

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Fuel Pump Gear Inspection
1. Perform gear inspection, if the gear passes visual inspection of the gear continue to checking end play. If the gear does not pass inspection replace the gear.

Illustration 49 g06266455

2. With the gear standing upright on a table, hold the outer gear tightly with one hand while trying to rotate the inner hub with the other hand. 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 50 g06026282

Illustration 51 g06266456

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 Illustration 52 g06026327

3. Fasten tooling FT3302 with two bolts and nuts.

Illustration 53 g06026334

4. Place the plate from tooling FT3302 on a suitable work surface. Secure the plate to the work surface. The clamps used to secure the plate must be outside the radius of the
pins.

Illustration 54 g03891436

5. Place the dial indicator into a hole next to tooling FT3302. Zero dial indicator.

Illustration 55 g03891400

6. Attach torque wrench to tooling FT3302. Apply 35 N·m (26 lb ft). Observe TIR reading and record when 35 N·m (26 lb ft) is reached. The limit for reuse is 0.045 mm
(0.0018 inch) at 35 N·m (26 lb ft). If the gear does not meet the TIR specification the gear should be replaced. The gear is not serviceable.

Wear Limit for Bronze Thrust Washers

Table 4
Hub Motion Relative to the Gear

Radial Axial
New 0.06 - 0.12 mm (0.00236 - 0.00472 inch) 0.19 - 0.31 mm (0.00748 - 0.01220 inch)

Maximum Wear 0.15 mm (0.00591 inch) 0.037 mm (0.00146 inch)

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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 56 g06323759
Visual reference example of C175 and 3500 auxiliary shafts

Illustration 57 g06323789
Visual reference example of C175 oil & water pump shafts

Illustration 58 g06324088
Visual reference example of C175 idler shafts

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Illustration 59 g06332367 Caterpillar: Confidential Yellow
Visual reference example of 3500 PTO shafts

Illustration 60 g06324150
Visual reference example of C175 PTO shafts

Illustration 61 g03327456
Check the splines of the gear shaft for wear steps.

Examples of Acceptable Wear on Gear Shafts

Nicks and Dings

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

Illustration 62 g03326412
Use Again if Shaft Meets Minimum Specifications.

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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.

Illustration 64 g03327542
Use Again if Shaft Meets Minimum Specifications.

Illustration 65 g03327546
Use Again if Shaft Meets Minimum Specifications.

Other Acceptable Damage Types

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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.

Examples of Unacceptable Wear on Gear Shafts

Gear shafts can be reused as long as the shaft meets the minimum specifications in the critical areas shown in Illustration 56 - 60. Shafts with small nicks are acceptable, and the
shaft must meet minimum specifications and there are no raised material surrounding the nick.

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.

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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

Illustration 71 g06332338

Table 5
Auxiliary, Oil & Water Pump Shaft Diameters and Surface Textures

Part Diameter of Shorter End Surface Texture of Shorter Minimum Length (C) for Diameter of Longer End of Surface Texture of Longer
Number of Shaft (A) End of Shaft (B) Surface Texture of (E) Shaft (D) End of Shaft (E)

Ø 74.9 ± 0.015 mm
246-6691
(2.949 ± 0.0006 inch)

Ø 74.9 ± 0.015 mm Ø 93.9 ± 0.015 mm

251-5516 0.80 µm (31.49606 µinch) Ra 40 mm (1.575 inch) 0.80 µm (31.49606 µinch) Ra
(2.949 ± 0.0006 inch) (3.696 ± 0.0006 inch)

259-2489 Ø 74.9 ± 0.015 mm

331-3656 (2.949 ± 0.0006 inch)

Specifications for Idler Shafts

Illustration 72 g06332334

Table 6
Idler Shaft Diameters and Surface Textures

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

Ø 89.88 ± 0.02 mm 0.80 µm (31.49606 µinch) Ra

7C-3260
(3.53858 ± 0.00079 inch)
Ø 105.88 ± 0.02 mm
250-9947
Ø 129.86 ± 0.05 mm (4.16850 ± 0.00079 inch)
5.5 µm (216.5354µinch) Ra
(5.11259 ± 0.00197 inch) Ø 89.88 ± 0.02 mm
277-6911
(3.53858 ± 0.00079 inch)
Ø 105.88 ± 0.02 mm
282-8915
(4.16850 ± 0.00079 inch)
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329-8192 Ø 161.73 ± 0.05 mm < 3.5 µm (< 137.7953 µinch) Ra Ø 119.814 ± 0.012 mm Caterpillar: Confidential Yellow
(6.36731 ± 0.00197 inch) (4.71708 ± 0.00047 inch)
 430-8141

Specifications for PTO Shafts

Illustration 73 g06332666

Illustration 74 g06332700

Table 7
PTO Shaft Diameters and Surface Textures

Part Surface Surface Surface

(K) (M) (P) (S)
Number Texture (L) Texture (N) Texture (R)

1.6 µm
Ø 59.946 ± 0.013 mm Ø 63.42 ± 0.013 mm Ø 95.0 ± 0.015 mm Ø 63.42 ± 0.013 mm
4P-3743 (62.99213 µinch)
(2.36007 ± 0.00051 inch) (2.49685 ± 0.00051 inch) (3.74015 ± 0.00059 inch) (2.49685 ± 0.00051 inch
Ra

Ø 95.0 ± 0.015 mm
289-6329 35 µm 0.2 µm < 3.5 µm
Ø 57.897 ± 0.05 mm Ø 63.43 ± 0.01 mm (3.74015 ± 0.00059 inch) Ø 63.43 ± 0.01 mm
(1377.953 µinch) (7.87401 µinch) (< 137.7953 µinch)
(2.27940 ± 0.00197 inch) (2.49724 ± 0.00039 inch) Ø 101.5 ± 0.015 mm (2.49724 ± 0.00039 inch
290-1630 Ra Ra Ra
(3.99606 ± 0.00059 inch)

1.6 µm
Ø 59.946 ± 0.013 mm Ø 63.42 ± 0.013 mm Ø 95.0 ± 0.015 mm Ø 63.42 ± 0.013 mm
315-3096 (62.99213 µinch)
(2.36007 ± 0.00051 inch) (2.49685 ± 0.00051 inch) (3.74015 ± 0.00059 inch) (2.49685 ± 0.00051 inch
Ra

Sleeve Installation and Machining Procedure

Fuel Pump Adapter Assembly

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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 8
291-1998 and 354-1562 Pump Adapter Assembly with 318-4810 Bearing Sleeve

Dimension Description Dimension

A Bore diameter of adapter after sleeve installation 94.056 mm (3.70298 inch)

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).

Table 9
348-7075 Engine Oil Pump Adapter Assembly with 348-7074 Bearing Sleeve
Dimension Description Dimension

C Diameter of bearing bore after sleeving 75.023 mm (2.95366 inch)

Table 10
Former 247-3417 Engine Oil Pump Adapter Assembly with 127-5400 Bearing Sleeve
Rework with 348-7074 bearing sleeve with the dimensions below

Dimension Description Dimension

C Diameter of bearing bore after sleeving 75.0 ± 0.055 mm (2.95275 ± 0.00217 inch)

Front Adapter Assemblies

r120hxt
Caterpillar: Confidential Yellow
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 11
348-7076 Front Adapter Assemblies with 348-7074 Bearing Sleeve

Dimension Description Dimension

F Diameter of bearing bore after sleeving 75.035 mm (2.95413 inch)

Table 12
Former 248-7582 Front Adapter Assemblies with 127-5400 Bearing Sleeve
Rework with 348-7074 bearing sleeve with the dimensions below

Dimension Description Dimension

F Diameter of bearing bore after sleeving 75.0 ± 0.055 mm (2.95275 ± 0.00217 inch)

Low, Medium, and High-Speed Idler Gears

Illustration 78 g06312920

Table 13
Low, Medium, and High-Speed Idler Gear Assemblies

Part Number Machined Diameter of Bearing Sleeve After Installation (I) Installation Depth (J) Surface Texture (K)
307-2402 89.964 ± 0.01 mm (3.54188 ± 0.0004 inch)

312-1676 2.3 ± 0.5 mm (0.0905 ± 0.0197 inch) 0.80 µm (31.49606 µinch) Ra

105.98 ± 0.01 mm (4.1724 ± 0.0004 inch)
312-1677

Idler (Cluster) Gear and Shaft

r120hxt
Caterpillar: Confidential Yellow
Illustration 79 g06332306

Table 14
254-5886 Idler (Cluster) Gear with 254-5887 Bearing Sleeve
Dimension 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 (31.49606 µinch) Ra

Illustration 80 g06332307
Example of cluster gear shaft

Table 15
328-7113 Cluster Gear Shaft

Dimension Description Dimension

D Shaft Diameter 74.97 ± 0.01 mm (2.9516 ± 0.0004 inch)

E Surface Texture 0.13 µm (5.11811 µinch) Ra

r120hxt
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Illustration 81 g06312800
Example of idler and cluster gear

Table 16
Idler and Cluster Gear Specifications

Part Machined Diameter of Bearing Sleeve After

Surface Texture (F) Installation Depth (G) Diameter of Original Gear Bore (J)
Number Installation (H)

478-5468 0.80 µm 1 ± 0.5 mm 128.009 ± 0.013 mm

119.93 ± 0.01 mm (4.72164 ± 0.00039 inch)
478-5469 (31.49606 µinch) Ra (0.03937 ± 0.01969 inch) (5.03971 ± 0.00051 inch)

Illustration 82 g06312830
Example of auxiliary drive gear

Table 17
Auxiliary Drive Gear Specifications

Part Number Diameter of Original Gear Bore (K)

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

273-3816 101.551 ± 0.025 mm (3.99806 ± 0.00098 inch)

Salvage Procedures for Front and Rear Gear Train on 3500 Engines
On 3500 Engines, the bearing sleeves on the front gear train have been improved to increase the life of the bearing sleeve and the gear train reliability and 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

r120hxt
High-Speed Idler Gears Caterpillar: Confidential Yellow
 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 18
Part Numbers for the Bearing Sleeve
Description Former Bearing Sleeve New Bearing Sleeve

High-Speed Idler Gear Assembly 7N-5243 140-9597

Low Speed Idler Gear Assembly 8N-5301 116-1365

Adapter Assembly 7N-5244 127-5400

Affected Engines

The improvements to the 3500 Engines came in three stages. The first stage was the release of the new bearing sleeve for the low speed idler gear assembly. The engines with this
change and the serial numbers are listed in Table 19. All the attachments that are low speed drives that were made after October 1996have the new bearing sleeves on the front idler
gear assemblies.

Table 19
Effective Serial Numbers for Low Speed Idler Gear Assemblies

Model 3508 3512 3516

Industrial S/N:68Z874 N/A S/N:71Z324

Marine S/N:69Z717 N/A S/N:72Z518

Generator Set S/N:70Z952 N/A S/N:73Z768

S/N:1313 S/N:4KC567 S/N:3RC1113

Gas (Right Side) S/N:2JF325 S/N:5JD22 S/N:8LD28

S/N:9TG56 S/N:7NJ108 S/N:4EK510

S/N:2JF344 S/N:4KC640 S/N:3RC1201

Gas (Left Side) S/N:9TG123 S/N:5JD30 S/N:8LD38

N/A S/N:7NJ221 S/N:4EK1096

The second stage was the release of the new bearing sleeves on all adapter assemblies. All 3500 Engines that were manufactured after May 1996were built with the new bearing
sleeve on the front adapter assemblies.

The third stage was the release of the new bearing sleeve on all the high-speed idler gear assemblies that were manufactured after May 1997. The serial number ranges for this
change are shown in Table 20.

Table 20
Effective Serial Numbers for High-Speed Adapter Assemblies

Model 3508 3512 3516

Industrial S/N:95Y1019 S/N:49Y836 S/N:27Z776

S/N:96Y1731 S/N:50Y1519 S/N:29Z1235

S/N:7SM85 S/N:4TN101 S/N:4MJ177

Marine
S/N:2BM123 S/N:7HM176 S/N:8KN156

N/A S/N:8EM264 S/N:8CN146

Marine Auxiliary S/N:3DM94 N/A S/N:9AN122

S/N:23Z6906 S/N:24Z8021 S/N:25Z5597

S/N:6PN302 S/N:8RM216 S/N:4XF678

Generator Set S/N:4GM224 S/N:6WN142 S/N:5SJ547

N/A N/A S/N:7RN473

N/A N/A S/N:6HN162

Locomotive S/N:6TJ14 S/N:2WK76 S/N:9KF104

Vehicular S/N:97Y718 S/N:51Y761 S/N:28Z649

r120hxt
Petroleum N/A S/N:1LM142 N/A
Caterpillar: Confidential Yellow
 Gas S/N:2JF349 S/N:4KC646 S/N:3RC1228

S/N:9TG148 S/N:7NJ303 S/N:4EK1352

N/A N/A S/N:5PN35

D11N

776B S/N:99W3520 N/A N/A

777B

D11R
5130
S/N:7YG2092 N/A N/A
776C

777C

D11R

992G
S/N:2GR744 N/A N/A
776D

777D

789

793 N/A N/A S/N:54Z1170

994
789B

793B N/A N/A S/N:2PK1455

5230

793C
N/A N/A S/N:7TR402
994G

Table 21
Front Gear Train

Item Part Number Description Option 1 Option 2 Option 3

144-8263 144-8263 N/A N/A

7E-0274 144-8263 N/A N/A

111-8145 144-8263 N/A N/A
1 Idler Gear Assembly(1)
116-3242 116-3242 N/A N/A

2W-7321 116-3242 N/A N/A

2W-0548 153-1243 N/A N/A

140-9597 N/A 140-9597 7N-5243

7N-5243 N/A 140-9597 7N-5243
2 Bearing Sleeve
116-1365 N/A 116-1365 8N-5301

8N-5301 N/A 116-1365 8N-5301

4P-0668 4P-0668 N/A N/A

7C-4164 7C-4164 N/A N/A

7C-4165 7C-4165 N/A N/A

7E-6748 7E-6748 N/A N/A

7N-5245 7N-5245 N/A N/A

3 Adapter Assembly(2)
7N-5263 7N-5263 N/A N/A

7N-5279 7N-5279 N/A N/A

8N-8210 8N-8210 N/A N/A

107-0779 107-0779 N/A N/A

107-7362 107-7362 N/A N/A

127-5400 N/A 127-5400 N/A

4 7N-5244 Bearing Sleeve N/A 127-5400 N/A

2S-7056 N/A N/A 2S-7056 r120hxt
(1)
Caterpillar: Confidential Yellow
Idler gear assemblies come with bearing sleeves that are installed and machined.
(2) Adapter assemblies come with bearing sleeves that are installed.

Table 21 shows the new part numbers for the idler gear and adapter assembly and the former part numbers for the idler gear and adapter assembly.

Note: All affected adapter assemblies are listed in table 21.

Reconditioning the Components of the Front Gear Train

Three options are available when the idler gear and adapter assembly in the front gear train are being reconditioned.

1. Replace the idler gears and adapters with new parts.

2. Use the original gears and/or adapters with new high strength bearing sleeves.

3. Use the original gears with new bearing sleeves that are medium strength .

The required parts for the rework vary depending on the option that is used to recondition the gear train. Table 21 shows the required parts for each particular option for rework.

Option 1

If idler gear (4) and adapter assembly (1) are replaced with new parts, no further rework is required. The new parts will have the new high strength bearing sleeve that will be
installed, and the idler gears will be machined for the finish.

Option 2

If original idler gear (4) and/or adapter (1) is reused, new high strength bearing sleeves (2 and 3) must be pressed into the gear or the adapter. Idler gear assemblies must then be
machined. Refer to the section: "Sleeve Installation and Machining Procedure" within this document. No machining for the finish is required for the adapter assembly.

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

Original idler gear (4) and new bearing sleeves that are medium strength (2) and (3) with the overlay that is lead tin can be used if there is no evidence of bearing cavitation or
fatigue. If the procedure for machining for the finish cannot be completed on the bearing that is high strength, use the bearing sleeve that is medium strength. After the bearing
sleeves that are medium strength are installed, no machining is required.

Sleeve Installation and Machining Procedure

When bearing sleeves are replaced, use the installation and the removal procedure in the appropriate Service Manual. The same removal procedure for the former bearing sleeves is
used for new bearings.

The specifications in the Table 22 are for installation and the machining of the inside diameter of the new bearing sleeves.

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

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

Illustration 83 g01509263
The illustration shows items for the bearing sleeve in the idler gear assembly. Refer to Table 22 for identification of the items and dimensions.

Table 22
Specifications for Bearing Sleeve

Dimension Description

(A) 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch)(1)(2) r120hxt

Caterpillar: Confidential Yellow
 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).
(3) Low speed idler gears.

3500 Rear Gear Train

Table 23
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) N/A N/A 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 15-5283 15-5283 N/A

101-1374(2) N/A 125-9751 125-9751 N/A

125-9751 N/A 125-9751 125-9751 N/A

121-4750 N/A 121-4750 121-4750 N/A

1N-3986(4) 4P-5091 4P-5091 4P-5091 101-1368

4P-5091 4P-5091 4P-5091 4P-5091 101-1368

2 Thrust Washer N/A
101-2983 101-2983 101-2983 101-2983 101-1368
101-1368 101-1368 101-1368 101-1368 N/A

4 0S-1595 Bolt 0S-1595 N/A N/A N/A N/A

4W-4998 4P-5437 4P-5437 N/A N/A

4W-5014 4P-5456 4P-5456 N/A N/A

4P-5437 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

r120hxt
4 1A-5822 Bolt 1B-4367 1B-4367 1B-4367 1B-4367 1B-4367 Caterpillar: Confidential Yellow
 1B-4367
2 8S-2331 Bolt 8S-2331 N/A N/A N/A 8S-2331

7N-6983 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

1 Bearing Sleeve(6) N/A
4P-5460 N/A 4P-5460 4P-5460 4P-5460
115-5279 N/A 115-5279 115-5279 115-5279

101-1372 N/A 101-1372 101-1372 N/A

1D-4609 9X-8887 9X-8887 9X-8887 9X-8887

2 Bolt 9X-8887
9X-8887 N/A N/A N/A N/A

2 5P-8246 Hard Washer 5P-8246 N/A N/A N/A N/A

7E-8777(2) 4P-5459 N/A N/A N/A

7E-3891(2) 4P-5457 N/A N/A N/A

7E-8779(2) 107-2477 N/A N/A N/A

7E-8781(2) 4P-5458 N/A N/A N/A

4P-5459 4P-5459 N/A N/A N/A

4P-5457 4P-5457 N/A N/A N/A

4P-5441(2) 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
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 23 to determine which parts must be replaced. The parts that are listed in the Replace as Needed column should be checked during each rebuild. The
parts that are listed under the column, Option, are the parts that are required for that particular option for rework. Some parts are not common with all engine models. Those parts are
the assemblies of the cluster idler gear, the bearing sleeves, and the shafts. For these parts, order the part number that is required for the specific engine model. Not all the parts in the
gear group have changed.

Improvements to the Rear Gear Train

Several changes were made to improve the service life and reliability of the rear gear train. These changes include new gears, bearing sleeves, and gear shafts. As a result of
reconditioning or replacing existing parts, older engines can gain the same benefits as newer engines.

The following list of improvements is divided into two sections: 3500 and 3500B Changes that affect both series of engines will be discussed in each section.

3500

New drive gears for the cam, idler gears, and cluster gears are used. The new parts now have a deeper depth of the case of hardened material. The new parts are case
carburized.
r120hxt
A new 100-8310 Rear Gear Gp has been developed. The new rear gear group is a direct replacement for the former 4W-5906 Rear Gear Gp. The new gear group
Caterpillar: is now Yellow
Confidential
effective with all the 3516 marine engines. The serial number 4MJ34 is adapted with the new gear group. The gear group is adaptable to all earlier engines. The new 100-6518
 Camshaft Drive Gear that is heavier has increased rotational inertia. This improvement has lowered the mesh torques for gear to gear, which has resulted in an increase of the
service life of the gear.

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 aluminum bearing sleeves with steel backing to bronze bearing sleeves with steel backing.
This change will increase the resistance to fatigue for the bearing.

The cluster and idler gear shafts are slightly larger in diameter. This change reduces the clearance between the shaft and the sleeve bearings to minimize the wobble of the
gear.

The new shafts for the cluster gear and the idler gear have two smaller oil supply holes instead of one hole with a large diameter. This improvement will provide better
distribution of the oil to the bearing sleeve.

Idler gear shafts have a thicker flange to prevent breakage at the corners of the half flange.

The bolt pattern and shaft diameter of the idler gear shaft has been changed. The new shaft has a bolt hole pattern with three bolt holes instead of a bolt hole pattern with 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.

A new bronze bearing sleeve with a steel backing 125-9751 bearing sleeve has been released with a larger outer diameter to increase the interference fit between the gear and
bearing sleeve. This bearing sleeve will result in better retaining of the bearing sleeve in the camshaft idler gear assembly.

The interference fit between the small cluster gears and the large cluster gears has been increased. This increase will provide the retention of the joint and will reduce the risk
of slippage of the joint of the gear.

The cylinder block and the idler gear thrust washers have been changed to accept the three bolt hole pattern.

3500B

With the release of the 3500B, the pitch of the small cluster, idler, and camshaft drive gear has been changed from 10 to 8. The reduced pitch provides better carrying
capability for torque.

The interference fit between the small cluster gears and the large cluster gears has been increased. This increase will provide the retention of the joint and will reduce the risk
of slippage of the joint of the gear.

The following sections in this guideline describe the specifications and procedures to recondition existing parts to take advantage of the listed improvements.

Engines That Were Affected By The Improvements

The improvements to the 3500 Engines came in several stages. The first stage included the replacement of the former gears with the new case carburized gears. The engines and the
serial numbers that were affected by this change are listed in Table 24.

The second stage incorporated the introduction of the new bronze bearing sleeves with steel backing, the change in diameter and number of oil feed holes to the cluster and idler
shafts, and the change to provide a thicker flange on the idler shaft. Also, the bolts that secure the idler shaft were changed from 1/2-13 to 5/8-11. Table 25 lists the engines that are
affected by these changes. Engines that are first listed in the Table 25 include the change to the case carburized gears.

The third stage included the increase in the number of bolts that secure the idler shaft from two bolts to three bolts. Also, a common block was provided for 3500 and 3500B
Engines. Refer to Special Instruction, SEHS9826, "Ordering "Series B" Replacement Cylinder Blocks for 3500 Series Engines" for more information. Table 26 lists the engines and
the serial numbers that are affected by this change.

The next stage was to release 8 pitch gears for 3516-Phase II Marine and Generator Set Engines. The effective serial numbers for the affected engines are listed in Table 27.

Next, the interference fit between the idler gear and bearing sleeve was increased. Table 28 lists the engines and the serial numbers that are affected by this change.

Next, the interference fit between the small cluster gear and the large cluster gear was increased. The effective serial numbers for the affected engines are listed in Table 29.

Note: Not all serial numbers are listed in Table 29. All engines that were manufactured after June 1995contain cluster gears with an increased interference fit.

Table 24
Effective Serial Numbers for Case Carburized Gears in Rear Gear Trains (Camshaft Drive)

Model 3508 3512 3516

Industrial N/A S/N:65Z715 S/N:71Z297

Marine N/A S/N:66Z423 S/N:72Z415

r120hxt
Generator Set (low speed) N/A S/N:67Z794 S/N:73Z405 Caterpillar: Confidential Yellow
 D11N S/N:99W1942 N/A N/A

776B
777B

789 N/A S/N:54Z661 N/A

Table 25
Effective Serial Numbers for Changes to the Cluster and Shaft of the Idler Bearing Sleeve

Model 3508 3512 3516

Industrial S/N:95Y791 S/N:49Y606 S/N:27Z693

Industrial S/N:68Z776 S/N:65Z724 S/N:71Z302

S/N:29Z967
Marine S/N:96Y1147 S/N:50Y948 S/N:4MJ34
S/N:5MJ33
Marine S/N:69Z562 S/N:66Z434 S/N:72Z427

S/N:23Z3671 S/N:24Z3920 S/N:25Z226

Generator Set
S/N:1ZF593 S/N:3YF604 S/N:4XF382

Generator Set (low speed) S/N:70Z775 N/A S/N:73Z463

Locomotive N/A N/A S/N:9KF56

Vehicular S/N:97Y673 S/N:51Y629 S/N:28Z625

D11N
776B S/N:99W2752 N/A N/A

777B

785 N/A S/N:96Z740 N/A

789 N/A S/N:54Z719 N/A

Table 26
Effective Serial Numbers for Idler Shafts with Three Bolt Hole Patterns
Model 3508 3512 3516

Industrial S/N:95Y942 S/N:49Y741 S/N:27Z759

Industrial S/N:68Z838 S/N:65Z805 S/N:71Z318

S/N:29Z1120
Marine S/N:96Y1485 S/N:50Y1317 S/N:4MJ162
S/N:5MJ33

Marine S/N:69Z664 S/N:66Z579 S/N:72Z427

S/N:25Z4283
Generator Set S/N:23Z5701 S/N:24Z6028 S/N:4XF572
S/N:5SJ289

Generator Set (low speed) S/N:70Z887 S/N:67Z1185 S/N:73Z682

Locomotive S/N:6TJ12 S/N:2WK40 S/N:9KF80

Vehicular S/N:97Y688 S/N:51Y731 S/N:28Z635

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

S/N:2JF302 S/N:4KC557 S/N:3RC1072
Gas
S/N:9TG27 S/N:5JD19 S/N:4EK374
D11N

776B S/N:99W3447 N/A N/A

777B

D11R

5130
S/N:7YG959 N/A N/A
776C

777C

785 N/A S/N:96Z912 N/A

785B N/A N/A S/N:4WJ535

789 N/A S/N:54Z1069 N/A r120hxt

Caterpillar: Confidential Yellow
793
 994

789B

793B N/A S/N:2PK679 N/A

5230

Table 27
Effective Serial Numbers for the Introduction of 8 Pitch Gears

Model 3508 3512 3516

Marine N/A N/A S/N:4MJ150

S/N:5SJ162
Generator Set N/A N/A
S/N:4XF460

Table 28
Effective Serial Numbers for 125-9751 Bearing Sleeve
Model 3508 3512 3516

Industrial S/N:95Y968 S/N:49Y760 S/N:27Z762

Industrial S/N:68Z843 S/N:65Z831 S/N:71Z318

S/N:29Z1168
Marine S/N:96Y1563 S/N:50Y1383
S/N:5MJ33

Marine S/N:69Z685 S/N:66Z613 S/N:72Z481

S/N:23Z6191 S/N:25Z4726
Generator Set S/N:24Z6689
S/N:8TL3 S/N:4XF606

Generator Set (low speed) S/N:70Z925 S/N:67Z1286 S/N:73Z701

S/N:9KF103
Locomotive S/N:6TJ14 N/A
S/N:5PN35
Vehicular S/N:97Y697 S/N:51Y740 S/N:28Z637

Petroleum N/A S/N:1LM67 N/A

S/N:2JF330 S/N:4KC593 S/N:3RC1126

Gas S/N:9TG67 S/N:5JD23 S/N:4EK600
S/N:4WD13 S/N:7NJ133 S/N:8LD28
D11N

776B S/N:99W3487 N/A N/A

777B

D11R

5130
S/N:7YG1438 N/A N/A
776C

777C

785 N/A S/N:96Z913 N/A

785B N/A S/N:4WJ643 N/A

789
793 N/A N/A S/N:54Z1117

994

789B

793B N/A N/A S/N:2PK906

5230

Table 29
Effective Serial Numbers for the Increased
Interference Fit Cluster Gear.

Model 3508 3512 3516

Marine N/A N/A S/N:8KN68

S/N:5SJ353
Generator Set N/A N/A
S/N:4XF593

Locomotive N/A N/A S/N:5PN35 r120hxt

Caterpillar: Confidential Yellow
 Gas N/A S/N:5JD20 S/N:4EK371
S/N:7NJ73 S/N:8LD28
785B N/A S/N:4WJ545 N/A

789B

793B N/A N/A S/N:2PK680

5230

Reconditioning the Components of the Rear Gear Train

Four options are available for reconditioning the drive group for the rear gear train. These options are listed as following.

1. Replace all the parts in the gear train.

2. Use the original gears with new bronze bearing sleeves and shafts.

3. Use the original shafts and gears with new bronze bearing sleeves.

4. This option is for the required rework, when a replacement block is used.

The parts that are required for the rework may vary depending on the option that is used to recondition the gear train. Table 23 shows the part number, under the column, Option,
which is required for that particular option for rework. Each option is explained in more detail below.

Option 1

If all the gears and the shafts in the rear gear train are replaced, then modifying or reworking of the bolt holes which retain the idler gear shaft (8) is the only action that is needed. If
the current engine block has 5/8-11 threaded holes or a pattern of three bolt holes, then no modification is necessary. If the holes are 1/2-13, then the holes must be drilled and tapped
according to the rework procedure. "Rework of Bolt Holes in Cylinder Block" 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, then the new bearing sleeves must be pressed into the gear and machined to a finish.

Idler gear shafts (8) and the shaft for the cluster gear (8) must also be reworked for a second oil hole, if necessary. This rework procedure is contained in the "Reworking Idler and
Cluster Gear Shafts" section.

Option 4

If the original cylinder block has two 1/2-13 or two 5/8-11 tapped holes for the shaft of the rear camshaft idler gear and the replacement block has three tapped holes, new idler gears
(3) and idler gear shafts (8) are required. The original cluster gear (14) and the shaft of the cluster gear (7) can be used again. If the original cluster gear assembly is used again, then
new bronze bearing sleeves must be pressed into the gear and machined to a finish. The "All Camshaft Idler Gear and Cluster Gear Assemblies" section provides a procedure for this
operation. The shaft of the cluster gear (8) must also be reworked for a second oil hole, if necessary.

Note: Maintain the correct clearance between the shaft and idler gear and cluster gear. The clearance in diameter between the shaft and idler gear is 0.060 ± 0.020 mm
(0.0024 ± 0.0008 inch). The clearance in diameter between the shaft and cluster gear is 0.070 ± 0.020 mm (0.0028 ± 0.0008 inch). Prior to machining the bearing sleeve, take a
measurement from the shaft and maintain the above clearance.

Rework of Bolt Holes in Cylinder Block

One improvement to the gear group was the increase of the size of the bolts (9) that retain the idler shaft to the cylinder block. This rework procedure contains the tool list,
instructions, and dimensions for drilling and tapping the bolt holes for the idler shaft.

Reconditioning the bolt holes of the idler shaft in the block is an acceptable repair, and will cost less than replacing the cylinder block.

Tooling

Illustration 85 g02515196
The illustration shows the tools that are required for the rework procedure. Refer to Table 30 for the part numbers and the description.

Table 30
r120hxt
Required Tooling Caterpillar: Confidential Yellow
 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

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, 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).
r120hxt
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 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 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/
r120hxt
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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 ( 1N-4054 Idler Shaft, 4W-4998 Gear Shaft, or 4W-5014 Idler Shaft) are
used again, then the shafts must be reworked to provide a second oil hole. This oil hole is made by extending the current oil hole through to the other side of the shaft.

The oil hole of the shaft can be drilled on a small drill press. The shaft must be clamped in a vise. The speed of the spindle should be approximately 440 rpm. Illustrations 93 and 94
show the new style of shafts which have through oil holes. Use the following procedure to add the second oil hole.

r120hxt
Caterpillar: Confidential Yellow
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 31 for reference dimensions.

r120hxt
Caterpillar: Confidential Yellow
 Illustration 96 g06177165
The illustration shows an idler gear assembly. Refer to Table 31 for reference dimensions.

2. After the bearing sleeve is installed, then hone the inside diameter to dimension (A) for the cluster gear or the idler gear.

Table 31
Specifications for Installing and Machining Bearing Sleeves

Item Description

75.060 ± 0.010 mm (2.9550 ± 0.0004 inch)(1)

(A)
81.060 ± 0.010 mm (3.1913 ± 0.0004 inch)(1)(2)

(B) 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(C) Pitch diameter must be concentric with a total indicator reading (TIR) of 0.15 mm (0.006 inch)or less.
(D) The surface of the gear must be square with the bore within 0.05 mm (0.002 inch).

(E) 1.00 ± 0.25 mm (0.040 ± 0.0010 inch)

(F) Pitch diameter must be concentric with a total indicator reading (TIR) of 0.12 mm (0.005 inch) or less.
(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 bronze-faced, steel-backed replacement bearing sleeve for stub shaft mounted idler gears on Cat engines. This procedure is a
robust and repeatable process to salvage idler gears. If the procedures found in this guideline are followed, bearing sleeves can successfully be pressed and machined into idler gears.

It is critical to the gear assembly that the surface texture and diameter are checked 100% and are within specifications.

When setting up and locating the gear in the machine, it is critical that the Pitchline TIR (process datum location), and Perpendicular TIR are checked. The locating gage pins for
the pitch line must be used (refer to Table 32 and 33). Failure to align the bearing sleeve for machining and check required machining specifications, can cause gear train
failures.

The surface texture on the inside diameter after machining shall not exceed 0.80 µm (31.49606 µinch) Ra on any bearing sleeve.

Shafts must also meet the specification for reuse.

Machine the bearing sleeve to print tolerance found in Table 32 and 33.

The machining process must use the pitch line of the gear for locating.

Specifications

The surface texture on the inside diameter after machining shall not exceed 0.80 µm (31.49606 µinch) Ra on any bearing sleeve in Table 32 and 33.

Table 32
Idler Gear and Shaft Specifications for Bronze Backed Bearing Sleeve

Gear As Bearing Max Gear

Nominal Machined Bearing Sleeve Depth in
Part Sleeve Part Pitchline TIR(1) Gear Gage Pin Size(s)
Bearing Sleeve I.D. Face TIR(2) the Gear
Number Number

4P-3130
9Y-1539 150.002 ± 0.002 mm 3 ± 0.5 mm
130-5478 N/A N/A 10 mm (0.39370 inch)
432-4362 (5.90558 ± 0.00008 inch) (0.11811 ± 0.01968 inch)
512-3024
75.06 ± 0.01 mm 0.05 mm 1 ± 0.25 mm
4P-5440 125-9750 0.12 mm (0.00472 inch) 4.7625 mm (0.18750 inch)
(2.95511 ± 0.00039 inch) (0.00197 inch) (0.03937 ± 0.00984 inch)

4.7625 mm (0.18750 inch) and the

75.06 ± 0.01 mm 0.05 mm 1.5 ± 0.5 mm
4P-5457 4P-5460 0.15 mm (0.00591 inch) Gear 2-gage pin size is 6.35 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) (0.05906 ± 0.01968 inch)
(0.25000 inch)

4.7625 mm (0.18750 inch) and the

75.06 ± 0.01 mm 0.05 mm 1.5 ± 0.5 mm
4P-5458 4P-5460 0.15 mm (0.00591 inch) Gear 2-gage pin size is 6.35 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) (0.05906 ± 0.01968 inch)
(0.25000 inch)

5 mm (0.19685 inch) and the Gear 2-

75.06 ± 0.01 mm 0.05 mm 1.5 ± 0.5 mm
4P-5459 4P-5438 0.15 mm (0.00591 inch) gage pin size is 6.35 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) (0.05906 ± 0.01968 inch)
(0.25000 inch) r120hxt
Caterpillar: Confidential Yellow
101-1363 101-1372 75.06 ± 0.01 mm 0.15 mm (0.00591 inch) 0.05 mm 6 mm (0.23622 inch) and the Gear 2- 1.5 ± 0.5 mm
 (2.95511 ± 0.00039 inch) (0.00197 inch) gage pin size is 5 mm (0.19685 inch) (0.05906 ± 0.01968 inch)

81.06 ± 0.01 mm 0.1 mm 1 ± 0.25 mm

101-1364 125-9751 0.15 mm (0.00591 inch) 6 mm (0.23622 inch)
(3.19133 ± 0.00039 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)

75.06 ± 0.01 mm 6 mm (0.23622 inch) and the Gear 2- 1.5 ± 0.5 mm

101-1377 4P-5460 0.15 mm (0.00591 inch) N/A
(2.95511 ± 0.00039 inch) gage pin size is 5 mm (0.19685 inch) (0.05906 ± 0.01968 inch)

0.15 mm (0.00591 inch) and 5 mm (0.19685 inch) and the Gear 2-

75.06 ± 0.01 mm 0.05 mm 1.5 ± 0.5 mm
107-2477 4P-5438 0.1 mm (0.0039 inch) for the gage pin size is 6.35 mm
(2.95511 ± 0.00039 inch) (0.00197 inch) (0.05906 ± 0.01968 inch)
inside gear (0.25000 inch)

81.06 ± 0.01 mm 0.05 mm 1 ± 0.25 mm

112-1554 125-9751 0.12 mm (0.00472 inch) 4 mm (0.15748 inch)
(3.19133 ± 0.00039 inch) (0.00197 inch) (0.03937 ± 0.00984 inch)

0.15 mm (0.00591 inch) and

75.06 ± 0.01 mm 0.05 mm 6 mm (0.23622 inch) and the Gear 2- 1.5 ± 0.5 mm
114-3372 101-1372 0.1 mm (0.0039 inch) for the
(2.95511 ± 0.00039 inch) (0.00197 inch) gage pin size is 5 mm (0.19685 inch) (0.05906 ± 0.01968 inch)
inside gear
81.06 ± 0.01 mm 0.1 mm 1 ± 0.25 mm
127-4628 125-9751 0.12 mm (0.00472 inch) 8 mm (0.31496 inch)
(3.19133 ± 0.00039 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)
0.15 mm (0.00591 inch) and 8 mm (0.31496 inch) and the Gear 2-
75.06 ± 0.01 mm 0.1 mm 1.5 ± 0.5 mm
136-3277 101-1372 0.1 mm (0.0039 inch) for the gage pin size is 12 mm
(2.95511 ± 0.00039 inch) (0.0039 inch) (0.05906 ± 0.01968 inch)
inside gear (0.47244 inch)

0.15 mm (0.00591 inch) and

128-2661 63.566 ± 0.013 mm 0.1 mm 5 mm (0.19685 inch) and Gear 2 is 2.8 ± 0.5 mm
149-9107 0.1 mm (0.0039 inch) for the
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) 6 mm (0.23622 inch) (0.11024 ± 0.01968 inch)
inside gear

81.06 ± 0.01 mm 0.1 mm 1 ± 0.25 mm

175-5197 125-9751 0.12 mm (0.00472 inch) 6 mm (0.23622 inch)
(3.19133 ± 0.00039 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)

0.15 mm (0.00591 inch) and

75.06 ± 0.01 mm 0.1 mm 6 mm (0.23622 inch) and the Gear 2- 1.5 ± 0.5 mm
175-5200 101-1372 0.1 mm (0.0039 inch) for the
(2.95511 ± 0.00039 inch) (0.0039 inch) gage pin size is 5 mm (0.19685 inch) (0.05906 ± 0.01968 inch)
inside gear
0.15 mm (0.00591 inch) and 8 mm (0.31496 inch) and the Gear 2-
185-1495 71.035 ± 0.013 mm 0.1 mm 2.5 ± 0.5 mm
224-9664 0.1 mm (0.0039 inch) for the gage pin size is 10 mm
331-6185 (2.79665 ± 0.00051 inch) (0.0039 inch) (0.09843 ± 0.01968 inch)
inside gear (0.39370 inch)

71.035 ± 0.013 mm 0.1 mm 2.6 ± 0.5 mm

185-1497 224-9664 0.1 mm (0.0039 inch) 8 mm (0.31496 inch)
(2.79665 ± 0.00051 inch) (0.0039 inch) (0.10236 ± 0.01968 inch)

0.15 mm (0.00591 inch) and

128-2661 63.566 ± 0.013 mm 0.1 mm 5 mm (0.19685 inch) and Gear 2- 2.8 ± 0.5 mm
187-8979 0.1 mm (0.0039 inch) for the
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) gage pin size is 6 mm (0.23622 inch) (0.11024 ± 0.01968 inch)
inside gear

0.15 mm (0.00591 inch) and

128-2661 63.566 ± 0.013 mm 0.1 mm 5 mm (0.19685 inch) and Gear 2 is 2.8 ± 0.5 mm
200-2454 0.1 mm (0.0039 inch) for the
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) 6 mm (0.23622 inch) (0.11024 ± 0.01968 inch)
inside gear
88.09 ± 0.013 mm 0.1 mm Center the bearing sleeve
206-4225 209-8621 0.1 mm (0.0039 inch) 10 mm (0.39370 inch)
(3.46810 ± 0.00051 inch) (0.0039 inch) in the gear
88.09 ± 0.013 mm 0.1 mm Center the bearing sleeve
207-8211 209-8621 0.1 mm (0.0039 inch) 10 mm (0.39370 inch)
(3.46810 ± 0.00051 inch) (0.0039 inch) in the gear

0.15 mm (0.00591 inch) and 8 mm (0.31496 inch) and the Gear 2-

88.09 ± 0.013 mm 0.1 mm 3.2 ± 0.5 mm
226-6036 226-6052 0.1 mm (0.0039 inch) for the gage pin size is 10 mm
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.12598 ± 0.01968 inch)
inside gear (0.39370 inch)

88.09 ± 0.013 mm 0.1 mm 3 ± 0.5 mm

228-5814 209-8621 0.1 mm (0.0039 inch) 10 mm (0.39370 inch)
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.11811 ± 0.01968 inch)

0.15 mm (0.00591 inch) and

71.035 ± 0.013 mm 0.1 mm 8 mm (0.31496 inch) and the Gear 2- 2.6 ± 0.5 mm
230-6202 224-9664 0.1 mm (0.0039 inch) for the
(2.79665 ± 0.00051 inch) (0.0039 inch) gage pin size is 4 mm (0.15748 inch) (0.10236 ± 0.01968 inch)
inside gear

137.91 mm 0.1 mm 1.5 ± 0.5 mm

243-3008 243-3007 0.25 mm (0.00984 inch) 10 mm (0.39370 inch)
(5.42952 inch) (0.0039 inch) (0.05906 ± 0.01968 inch)

0.15 mm (0.00591 inch) and 8 mm (0.31496 inch) and the Gear 2

75.06 ± 0.01 mm 0.1 mm 2 ± 0.5 mm
254-5886 254-5887 0.1 mm (0.0039 inch) for the gage pins size is 10 mm
(2.95511 ± 0.00039 inch) (0.0039 inch) (0.07874 ± 0.01968 inch)
inside gear (0.39370 inch)

0.15 mm (0.00591 inch) and

75.06 ± 0.01 mm 0.05 mm 6 mm (0.23622 inch) and the Gear 2- 1.5 ± 0.5 mm
261-3133 101-1372 0.1 mm (0.0039 inch) for the
(2.95511 ± 0.00039 inch) (0.00197 inch) gage pin size is 5 mm (0.19685 inch) (0.05906 ± 0.01968 inch)
inside gear

81.06 ± 0.01 mm 0.05 mm 1 ± 0.25 mm

261-3137 125-9751 0.12 mm (0.00472 inch) 6 mm (0.23622 inch)
(3.19133 ± 0.00039 inch) (0.00197 inch) (0.03937 ± 0.00984 inch)

0.15 mm (0.00591 inch) and 8 mm (0.31496 inch) and the Gear 2-

88.09 ± 0.013 mm 0.1 mm 3.2 ± 0.5 mm
261-3443 226-6052 0.1 mm (0.0039 inch) for the gage pin size is 10 mm
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.12598 ± 0.01968 inch)
inside gear (0.39370 inch)

88.09 ± 0.013 mm 0.1 mm 3 ± 0.5 mm

261-3445 209-8621 0.1 mm (0.0039 inch) 10 mm (0.39370 inch)
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.11811 ± 0.01968 inch)
271-5656 128-2661 63.566 ± 0.013 mm 0.15 mm (0.00591 inch) and 0.1 mm 4.7625 mm (0.18750 inch) and the 0.38 ± 0.25 mm r120hxt
(2.50259 ± 0.00051 inch) 0.1 mm (0.0039 inch) for the (0.0039 inch) Gear 2-gage pin size is 5 mm Caterpillar:
(0.01496 ±Confidential Yellow
0.00984 inch)
 inside gear (0.19685 inch)
0.15 mm (0.00591 inch) and 4.763 mm (0.18752 inch) and the
128-2661 63.566 ± 0.013 mm 0.1 mm 0.38 ± 0.25 mm
300-5575 0.1 mm (0.0039 inch) for the Gear 2-gage pin size is 5 mm
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) (0.01496 ± 0.00984 inch)
inside gear (0.19685 inch)

89.965 ± 0.01 mm 0.1 mm 2.3 ± 0.5 mm

307-2402 307-2403 0.1 mm (0.0039 inch) 10 mm (0.39370 inch)
(3.54192 ± 0.00039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)

75.06 ± 0.01 mm 0.05 mm 6 mm (0.23622 inch) and the Gear 2- 1.5 ± 0.5 mm
310-3177 101-1372 0.15 mm (0.00591 inch)
(2.95511 ± 0.00039 inch) (0.00197 inch) gage pin size is 5 mm (0.19685 inch) (0.05906 ± 0.01968 inch)

105.98 ± 0.01 mm 0.1 mm 2.3 ± 0.5 mm

312-1676 312-1678 0.1 mm (0.0039 inch) 10 mm (0.39370 inch)
(4.17243 ± 0.00039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)

105.98 ± 0.01 mm 0.1 mm 2.3 ± 0.5 mm

312-1677 312-1678 0.1 mm (0.0039 inch) 8 mm (0.31496 inch)
(4.17243 ± 0.00039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)

88.09 ± 0.013 mm 0.1 mm 3 ± 0.5 mm

320-6198 209-8621 0.1 mm (0.0039 inch) 10 mm (0.39370 inch)
(3.46810 ± 0.00051 inch) (0.0039 inch) (0.11811 ± 0.01968 inch)

128-2661 63.566 ± 0.013 mm 0.1 mm 6 mm (0.23622 inch) and the Gear 2- 2.8 ± 0.5 mm
352-9728 0.1 mm (0.0039 inch)
131-7123 (2.50259 ± 0.00051 inch) (0.0039 inch) gage pin size is 6 mm (0.23622 inch) (0.11024 ± 0.01968 inch)

63.566 ± 0.013 mm 0.1 mm 6 mm (0.23622 inch) and the Gear 2- Center the bearing sleeve
361-8233 128-2661 0.1 mm (0.0039 inch)
(2.50259 ± 0.00051 inch) (0.0039 inch) gage pin size is 6 mm (0.23622 inch) in the gear

81.06 ± 0.01 mm 0.1 mm 1 ± 0.25 mm

369-9356 125-9751 0.15 mm (0.00591 inch) 6 mm (0.23622 inch)
(3.19133 ± 0.00039 inch) (0.0039 inch) (0.03937 ± 0.00984 inch)

0.15 mm (0.00591 inch) and

75.06 ± 0.01 mm 0.05 mm 6 mm (0.23622 inch) and the Gear 2- 1.5 ± 0.5 mm
369-9357 101-1372 0.1 mm (0.0039 inch) for the
(2.95511 ± 0.00039 inch) (0.00197 inch) gage pin size is 5 mm (0.19685 inch) (0.05906 ± 0.01968 inch)
inside gear

10 mm (0.39370 inch) and the Gear

75.06 ± 0.01 mm 0.1 mm 1.5 ± 0.5 mm
386-2938 101-1372 0.1 mm (0.0039 inch) 2-gage pin size is 8 mm
(2.95511 ± 0.00039 inch) (0.0039 inch) (0.05906 ± 0.01968 inch)
(0.31496 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)
(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.

Note: All the bearing sleeves in Table 32 are Steel Backed Bronze Bearing Sleeves.

Table 33
Idler Gear and Shaft Specifications for Aluminum Backed Bearing Sleeves
Gear As Bearing
Nominal Machined Max Gear Bearing Sleeve Depth in
Part Sleeves Part Pitchline TIR(1) Gear Gage Pin Size(s)
Bearing Sleeves I.D. Face TIR(2) the Gear
Number Number
35.034 ± 0.038 mm 1.12 ± 0.25 mm
2W-4087 6N-0977 N/A N/A 4.7625 mm (0.18750 inch)
(1.37929 ± 0.00150 inch) (0.04409 ± 0.00984 inch)
7E-0274
7N-5243 90.0 ± 0.01 mm 0.1 mm 2.3 ± 0.5 mm
7N-5241 0.15 mm (0.00591 inch) 6 mm (0.23622 inch)
140-9597 (3.54330 ± 0.00039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)
144-8263

7E-3894 7N-5258 75.000 ± 0.055 mm 1.0 ± 0.25 mm

N/A N/A 4.7625 mm (0.18750 inch)
7N-5257 125-9750 (2.95275 ± 0.00217 inch) (0.03937 ± 0.00984 inch)

0.15 mm (0.00591 inch) and

7E-8779 75.0 ± 0.053 mm 4.0 mm (0.15748 inch) and Gear 1.5 ± 0.5 mm
7N-6983 0.1 mm (0.0039 inch) for the inside N/A
7N-6982 (2.95275 ± 0.00209 inch) 2 is 6.35 mm (0.25000 inch) (0.05906 ± 0.01968 inch)
gear

4.7625 mm (0.18750 inch) and

7E-8777 75.000 ± 0.053 mm 1.5 ± 0.5 mm
7N-6983 N/A N/A Gear 2 is 6.35 mm
8N-1266 (2.95275 ± 0.00209 inch) (0.05906 ± 0.01968 inch)
(0.25000 inch)

9Y- 55.163 ± 0.041 mm 1.0 ± 0.25 mm

7C-7852 N/A N/A 6 mm (0.23622 inch)
3520 (2.17177 ± 0.00161 inch) (0.03937 ± 0.00984 inch)

2W-7321
105.97 ± 0.01 mm 0.1 mm 2.3 ± 0.5 mm
8N-5299 116-1365 0.15 mm (0.00591 inch) 5.0 mm (0.19685 inch)
(4.17204 ± 0.00039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)
116-3242

69.385 ± 0.013 mm 1.0 ± 0.25 mm

132-3233 119-3776 N/A N/A 6 mm (0.23622 inch)
(2.73169 ± 0.00051 inch) (0.03937 ± 0.00984 inch)

69.205 ± 0.013 mm 0.1 mm 1.0 ± 0.25 mm

133-7086 133-7084 0.1 mm (0.00394 inch) 6 mm (0.23622 inch)
(2.72460 ± 0.00051 inch) (0.00394 inch) (0.03937 ± 0.00984 inch)

112.142 ± 0.01 mm 0.1 mm 2.3 ± 0.5 mm

136-3234 136-3244 0.15 mm (0.00591 inch) 6 mm (0.23622 inch)
(4.41503 ± 0.00039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)
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155-2307 116-1365 105.97 ± 0.01 mm 0.15 mm (0.00591 inch) 0.1 mm 5.0 mm (0.19685 inch) 2.3 ±
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Confidential
(4.17204 ± 0.00039 inch) (0.0039 inch) (0.09055 ± 0.01968 inch)
 180-3864 69.95 ± 0.01 mm 2.5 ± 0.5 mm
190-6465 N/A N/A 8 mm (0.31496 inch)
512-3006 (2.75393 ± 0.00039 inch) (0.09843 ± 0.01968 inch)

180-3865 69.95 ± 0.01 mm 2.5 ± 0.5 mm

190-6465 N/A N/A 8 mm (0.31496 inch)
512-3008 (2.75393 ± 0.00039 inch) (0.09843 ± 0.01968 inch)

69.205 ± 0.013 mm 0.1 mm 1.0 ± 0.25 mm

222-3905 133-7084 0.1 mm (0.00394 inch) 6 mm (0.23622 inch)
(2.72460 ± 0.00051 inch) (0.00394 inch) (0.03937 ± 0.00984 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 1.08 ± 0.25 mm

296-5412 296-5413 0.1 mm (0.00394 inch) 5 mm (0.19685 inch)
(2.91633 ± 0.00051 inch) (0.00394 inch) (0.04252 ± 0.00984 inch)

90.00 ± 0.01 mm 0.1 mm 2.3 ± 0.5 mm

355-5732 140-9597 0.15 mm (0.00591 inch) 10 mm (0.394 inch)
(3.543 ± 0.0004 inch) (0.0039 inch) (0.09055 ± 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.

Note: All the bearing sleeves in Table 33 are Steel Backed Aluminum Bearing Sleeves.

Machining a New Bearing Sleeve

Press in a New Bearing Sleeve

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

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. Since a fabricated tool must be made based
on Nominal Machined Bearing Sleeve I.D. and the Bearing Sleeve Depth in the Gear, a single fabricated tool will not work for all gear assemblies or bearing sleeves. Refer to Table 33 for the Nominal Machined Bearing
Sleeve I.D. and Bearing Sleeve Depth in the Gear Specifications.

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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.

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 of the gear lists a specific depth
for the bearing 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.
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Aligning the Gear
Locate the gear on the pitch line datum using the following procedure. Locating on the pitch line datum provides the most consistent and repeatable true position needed for the
bearing sleeve bore. The utilization of the pitch line datum minimizes the compounding errors from multiple machining operations and tolerances.

Note: The locating gage pins for the pitch line must be used (refer to Table 33). Failure to properly align the bearing sleeve for machining and check required machining
specifications, can cause gear train failures.

Each type of gear will require the use of a specific gage pin set. The gage pins are readily available commercially but also can be made. Care must be taken to precisely machine
these gage pins to specification due to the close tolerances of the gage pin diameters. If these gage pins are to be made, the use of 52100 alloy steel is recommended. These gage pins
are Class ZZ and have an allowed deviation of 0.00508 mm (0.00020 inch), geometry of 0.00254 mm (0.00010 inch), and a surface texture of 0.2540 µm (10.000 µin) Ra. Each gage
pin must be machined for each individual gear set according to specified dimensions. Refer to Tables 32 and 33 for correct gage pin size.

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.

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 33 for gage pin and gear matching information.

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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.

Continue to adjust the locating jaws until the reading of the dial indicator is within the tolerance listed in "Max Pitch TIR" within Table 33.

Illustration 107 g03307542

Check the face perpendicularly with the dial indicator, refer to Table 33 for the minimum specifications.

Adjust the surface of the gear until within "Maximum Gear Perpendicular Runout" specification found within Table 33. The gear is now centered by the pitch line and perpendicular
to the cutting machine. Recheck the gage pins to ensure that the face adjustment has not compromised the pitch adjustment.

Machining the Gear Bearing Sleeve

Note: If the stub shaft is to be reused, then check the stub shaft prior to machining the bearing sleeve.

The best results for machining the gear bearing sleeve is obtained by using two passes. The first pass will machine the bearing sleeve to within 0.051 mm (0.002 inch) or less. The
second and final pass will machine to final size and final surface texture. When done correctly, this two-step procedure will leave an acceptable finish requiring no further attention.

Note: The feed and RPM rates for your individual cutting tool, machine, and gear will vary to achieve the best surface texture. Various cutting tools have been used with different
RPM and feed rates to achieve similar results. For example, a Valenite cutter using a TNMP432 insert used at 1800 RPM and a 0.04572 mm (0.0018 inch) feed rate produced similar
results as a CNMG432MP insert at 850 RPM and a 0.04064 mm (0.0016 inch) feed rate.

Note: The required specifications for cutting aluminum bearing sleeves are in Section "Machining Aluminum Bearing Sleeves" below.

Illustration 108 g03784239

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Using high RPM and slow feed rate will produce the best finish results.
Machining Aluminum Bearing Sleeves

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

Inspection of Gear Bearing Sleeve After Machining

Checking Bearing Sleeve Diameter

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 33 for diameter specifications. Check the bore diameter at 3-4 different depths to assure there is no taper. Rotate
the gauge inside the bearing sleeve to check that the diameter is not out of round.

Note: The gauge resolution should be 10% of the tolerance window. So, 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, make sure that the bearing sleeve is clean and free of debris that could make the reading inaccurate.

Copyright 1993 - 2019 Caterpillar Inc. Thu Apr 25 2019 16:02:51 GMT-0400 (hora estándar de Chile)
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