- Caterpillar Products
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- All 3400 Engines
- All 3500 Engines
- All C175 Engines
- All G3500 Engines
- All 3400 Engines
Introduction
Revision | Summary of Changes in SEBF8170 |
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27 | Added new serial number prefixes for New Product Introduction (NPI) and 12 part numbers. |
25–26 | Combined information from SEBF2127, SEBF2144, SEBF2156, SEBF2161, SEBF9044, SEBF9198, added 4 part numbers and repaired 26 pixelated illustrations. |
24 | Added verbiage for C175 oil pump shafts. |
© 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 Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
Canceled Part Numbers and Replaced Part Numbers
This document does 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.
Important Safety Information
Illustration 1 | g02139237 |
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. 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, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
Summary
This guideline should be used for inspecting and measuring the components of a used engine oil pump, reconditioned engine oil pump, and front housings. This inspection and the measurement will determine if an engine oil pump can be used again. Often, the installation of a new engine oil pump is not necessary during an engine rebuild. The installation of a used oil pump or reconditioned oil pump can decrease costs of the engine rebuild. An engine oil pump that meets these guidelines for inspection and specifications can be expected to give normal performance in the same application until the next overhaul.
If this guideline indicates a part that cannot be used again, then never reuse the part. Individual components must be checked for recommended specifications. Before installing a used part or reconditioned part or a pump, correct any conditions that may have caused the original failure or wear.
Service Letters and Technical Information Bulletins
NOTICE |
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The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired. |
References
References | |
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Media Number | Title |
Channel1 | "Gear Tooth Inspection" |
https://channel1.mediaspace.kaltura.com/media/Gear+Tooth+Inspection/1_5ujdi5zp | |
"Why Reuse and Salvage Parts" | |
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z | |
SEBF2161 | Reuse and Salvage Guidelines, "Thermal Spray Procedures for 3500 Engine - Oil Pump" |
SEBF8187 | Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures". |
SEBF9066 | Applied Failure Analysis, "Guideline for Examining Failed Parts" |
SEBF9068 | Reuse and Salvage Guidelines, "Inspection Procedures for 3064 and 3066 MHI Engines for Caterpillar Built Machines" |
SEBF9240 | Reuse And Salvage Guidelines, "Fundamentals of Flame Spray for Reconditioning Components" |
SEBF9244 | Reuse and Salvage Guidelines, "Reuse and Salvage for Gear Train and Gear Shafts on Engines" |
SEHS9031 | Special Instruction, "Storage Procedure for Caterpillar Products" |
Tooling and Equipment
NOTICE |
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Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Required Tooling and Equipment | |
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Part Number | Description |
Driver | |
Dial Bore Gauge Kit | |
Soft Face Hammer | |
Polishing Stone | |
Depth Micrometer | |
Surface Texture Comparison Gauge | |
Dead Blow Hammer | |
Steel File | |
Lint Free Shop Towels | |
Dual Scale Feeler Gauge Set | |
Straight Edge Ruler | |
Spring Tester | |
Profilometer | |
or |
Internal Micrometer Set
2-12 inch |
Internal Micrometer Set
50-300 mm |
|
Outside Electronic Micrometer Set 0-4 inch |
|
Outside Electronic Micrometer Set 2-6 inch |
Replacement Parts
Consult the applicable Parts Identification manual for your engine.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. |
Preparation Recommendations
Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using. |
Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than |
- Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of an unacceptable defect.
- Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the part.
- During cleaning, do not damage machined surfaces.
- Do not use pressurized air to dry internal components. Compressed air has moisture and contaminants that can cause premature failure of internal components.
- Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately after cleaning. Carefully store the parts in a clean container.
- Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting from rust, nicks, and dents.
- Use appropriate thread taps to chase all threaded holes.
Standardized Parts Marking Procedure
Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".
The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.
Ensure that the mark is not covered by a mating part. 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
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 |
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Precise measurements shall be made when the component and measurement equipment are at |
3044, 3046, 3064, and 3066 Engines
Oil Pump Gears
After removing the gears from the oil pump, clean the components thoroughly. Inspect the gears for cracks, pitting, corrosion, the transfer of metal, or any other signs of abnormal wear.
If the gears will be stored after cleaning and inspection, coat the gears with a thin layer of engine oil. Store the gears in a clean, dry place. See "Storage Procedure" for additional information.
NOTICE |
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Keep all parts clean from contaminants Contaminants may cause rapid wear and shorten component life |
For more information regarding the wear patterns of gears, refer to Guidelines for Reusable Parts and Salvage Operations, SEBF9244, "Reuse and Salvage for Gear Train and Gear Shafts on Engines".
Front Housings and Covers
After removing the housing and the cover, clean the components thoroughly. Inspect the housing and the cover for cracks, pitting, erosion, or any signs of abnormal wear. Replace any component that is questionable.
Measure the bore diameters that are referenced in Table 4, Table 5, and Table 8. If the measurements are outside of the specifications, then the housing or the cover must be replaced.
If the housing and the cover will be stored after cleaning and inspection, coat the housing and the cover with a thin layer of engine oil. Store the housing and the cover in a clean, dry place. Reference "Storage Procedure" for additional information.
NOTICE |
---|
Keep all parts clean from contaminants Contaminants may cause rapid wear and shorten component life |
Specifications for the Front Housing(1)
3044 and 3046 Engines |
|
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Area | Dimension |
Diameter for the Bore for the Crankshaft Seal | |
Bore Diameter for the Front Bearing Support for the Camshaft Gear | |
Bore Diameter for the Support of the Hydraulic Pump Drive Gear(2) | |
(1) | Reference Table 8 for specifications for the oil pump as the specifications pertain to the front housing. |
(2) | This is applicable to engines that are equipped to drive hydraulic pumps. |
Specifications for Front Housings(1)
3064 and 3066 Engines |
|
---|---|
Area | Dimension |
Bore Diameter for the Crankshaft Seal | |
Bore Diameter for the Water Pump | |
(1) | Reference Table 8 for specifications for oil pumps as the specifications pertain to the front housing. |
The Measurement of Oil Pump Components
3044 and 3046 Engines
Illustration 6 | g06305612 |
(9) O-ring
(10) Inner rotor (11) Shaft (12) Outer rotor (13) Body |
Disassemble the oil pump. Clean all the components. Inspect all the components for cracks, pitting, or other obvious signs of wear.
Illustration 7 | g00987626 |
Clearance between the outer rotor and the body |
Use a feeler gage to measure the clearance between the outer rotor and the body. If the clearance exceeds
Illustration 8 | g00987627 |
Clearance between the inner rotor and the outer rotor |
Use a feeler gauge to measure the clearance between the inner rotor and the outer rotor. If the clearance exceeds
Illustration 9 | g00987628 |
Clearance between rotors and the body |
Use a feeler gauge and a straight edge to measure the clearance between the rotors and the body. If the clearance exceeds
Illustration 10 | g06305618 |
Measuring diagram for the oil pump shaft and oil pump housing |
Measure the diameter of the oil pump shaft and the diameter for the oil pump shaft in the oil pump body. Subtract the diameter for the oil pump shaft from the diameter of the oil pump housing. If the clearance exceeds
Illustration 11 | g06305621 |
Measuring diagram for the oil pump shaft and the bushing for the oil pump shaft |
Measure the diameter of the oil pump shaft and the inside diameter of the bushing in the engine block for the oil pump shaft. If the clearance exceeds
Note: Use the proper tool to install the oil pump bushing. Install the oil pump bushing so that the bushing is flush with the front face of the engine block.
3064 and 3066 Engines
Illustration 12 | g06305626 |
(1) Driven Gear Assembly
(2) Drive Gear Assembly (3) Oil Pump Gear (4) Idler Gear Assembly (5) Spindle |
Note: Items (2) and (3) are serviced as one unit. Do not remove oil pump gear (3) from drive gear assembly (2) until all the following inspections have been made.
Note: If either the driven gear assembly (1) or the drive gear assembly (2) must be replaced, then both of the gear assemblies must be replaced.
Illustration 13 | g06305628 |
(6) Housing |
Use a dial indicator or a depth micrometer to measure the distance between the end of the gears and the face of housing (6). Refer to Table 6 for the allowable distances. If the measurements are outside of the specifications, then the gear assemblies must be replaced.
Sales Model | Above(1) | Below(2) |
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3064 | |
|
3066 | |
|
(1) | The end of the gear is above the housing. |
(2) | The end of the gear is below the housing. |
Illustration 14 | g06305629 |
Use a feeler gauge to measure the clearance between the gears and the housing for both the 3064 and 3066 engines. The clearance must not exceed
Inspect the teeth of the gears for damage, cracks, or abnormal wear patterns. For more information regarding the wear patterns of gears, refer to Guidelines for Reusable Parts and Salvage Operations, SEBF9244, "Reuse and Salvage for Gear Train and Gear Shafts on Engines".
Illustration 15 | g06305639 |
(3) Oil Pump Gear
(4) Idler Gear Assembly |
Use a dial indicator to measure the backlash between oil pump gear (3) and idler gear assembly (4). The distance that is read on the dial indicator must be between
Inspect the teeth of the gears for damage, cracks, or abnormal wear patterns. For more information regarding the wear patterns of gears, refer to Guidelines for Reusable Parts and Salvage Operations, SEBF9244, "Reuse and Salvage for Gear Train and Gear Shafts on Engines".
Illustration 16 | g06305641 |
(6) Housing
(7) Cover |
Measure the bores on housing (6) and cover (7). Measure the diameter of the shaft at each end for the drive gear and measure the diameter of the shaft at each end for the driven gear. The clearance between the shaft and the housing and the clearance between the shaft and the cover should not exceed
Specifications for the Oil Pump Drive Gear and Driven Gear
3064 and 3066 Engines |
|
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Part | Dimension |
Shaft Diameter | |
Overall Diameter of the Gear | |
Specifications for the Front Housing and Cover for the Oil Pump
3064 and 3066 Engines |
|
---|---|
Part | Dimension |
Housing Inside Diameter(1) | |
Cover Inside Diameter | |
Diameter of the Bore for the Spindle | |
Clearance Between The Housing And The Shaft | Service Limit |
(1) | This diameter is for the drive and driven gears. |
Illustration 17 | g06305646 |
(5) Spindle
(8) Idler Gear Bushing |
Measure the inside diameter of idler gear bushing (8). If the measurement does not fall within
Measure the diameter of spindle (5) in the area of the rotation of the gear. If the measurement does not fall within
Idler Gear Shaft and Bore for the Idler Gear Shaft
Clean the idler gear shaft thoroughly after removing the idler gear shaft from the engine block. Inspect the idler gear shaft and the bore for the idler gear shaft in the engine block for damage, pitting, erosion, the transfer of metal or any signs of abnormal wear. Replace the idler gear shaft that is questionable.
Illustration 18 | g06305649 |
Reference for the idler gear shaft specifications |
Measure the idler gear shaft and the bore for the idler gear shaft in the engine block. Replace the idler shaft if the idler shaft does not meet the specifications. Refer to Table 9, Table 10, Table 11, and Table 12 for specifications.
Specifications for the Idler Gear Shaft
3044 and 3046 Engines |
|
Dimension | Reference To The Figure(1) |
|
14 |
|
15 |
|
16 |
|
17 |
(1) | Reference figure 18 for the areas for measuring. |
Specifications for the Bore for the Idler Gear Shaft
3044 and 3046 Engines |
|
Dimension | Reference To The Figure |
|
N/A |
Specifications for the Idler Gear Shaft
3064 and 3066 Engines |
|
Dimension | Reference To The Figure(1) |
|
14 |
|
15 |
|
16 |
|
17 |
(1) | Reference figure 18 for the areas for measuring. |
Specifications for the Bore for the Idler Gear Shaft
3064 and 3066 Engines |
|
Dimension | Reference To The Figure |
|
N/A |
3400 Engine Oil Pump
Illustration 19 | g06305653 |
(1) Pump cover assembly
(2) Sleeve Bearing (3) Input Drive Shaft (4) Pump body assembly (5) Cover assembly of the pump body (6) Hollow dowel (7) Cover (pressure relief valve) (8) Drive shaft assembly (9) Spring (pressure relief valve) (10) Spool (pressure relief valve) (11) Sleeve bearing |
3500 Engine Oil Pump
Illustration 20 | g01950004 |
Typical engine oil pump group for 3500 Family of Engines (1) Pump cover assembly, (2) Sleeve bearing, (3) Idler shaft assembly, (4) Pump body assembly, (5) Cover assembly of the pump body, (6) Hollow dowel, (7) Cover (pressure relief valve), (8) Drive shaft assembly, (9) Spring (pressure relief valve), (10) Spool (pressure relief valve), and (11) Sleeve bearing |
C175 Engine Oil Pump
Illustration 21 | g06305691 |
(1) Body Assembly
(2) Sleeve Bearing (3) Input Drive Shaft (4) Cover Assembly (5) Sleeve Bearing (6) Shaft Assembly |
Spool for Pressure Relief Valve
The relief valve spool for oil pressure and the spring should be visually inspected. The oil pump body and pump cover assembly should also be inspected. This inspection will determine if these components meet the specifications for reusability.
Check for an excessive wear groove on the outer surface of spool (10) as the spool appears to be cocked by the spring (9). Spools that have been polished for the removal of a wear groove should maintain a minimum diameter for reusability. Refer to Table 15 for the minimum diameter for reusability (J). If the spool is not within the minimum diameter for reusability, then the spool should be replaced.
Check for a wear groove on the inside of the spool. Particularly check the area that comes into contact with the spring. A wear groove could be deep enough to catch a coil of the spring which could affect the spring rate of the spring. If there is a wear groove on the valve spool, then the valve spool is not reusable and the valve spool should be replaced.
Spring for Pressure Relief Valve
Illustration 22 | g03680564 |
Use the |
Check for wear or nicks on spring (9). If the spring is slightly worn, then the spring might meet the specified spring force values in Table 15. In that case, the spring is reusable. Check the spring force with a valve spring tester, and use Table 15 for correct values for spring force and spring length.
NOTICE |
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Deep nicks on the spring could lead to breakage and result in pump damage. If there are deep nicks, do not reuse the valve spring. Replace it immediately. |
Pump Body Assembly and Pump Cover Assembly
Check for wear on the side of the oil pressure relief hole. Usually, this spot of wear can be removed by polishing. Check for wear in the bore of the oil pump. Specifically, check the contact area of the body and gears. This wear could possibly be cleaned up without exceeding the maximum depth for reusability, which is specified in table 15. If the bore of the oil pump does not exceed the maximum depth for reusability, then the oil pump body can be reused.
Illustration 23 | g06305699 |
Cavitation erosion on the body assembly |
Check for cavitation erosion in the body assembly and the pump cover assembly under the location of the center gear. Sometimes, numerous spots of cavitation may be present. However, both the pump body and the cover are reusable if the eroded areas do not exceed a maximum of
Note: If the cavitation on the body or the cover exceeds the maximum limit, use the salvage procedure of flame spray. For the salvage procedure of flame spray, refer to Reuse And Salvage Guidelines, SEBF9240, "Fundamentals of Flame Spray for Reconditioning Components".
Oil Pump Gears
It is important for the gears to be cleaned prior to inspection. After removing the gears from the oil pump, clean the gears to make sure that the gears are free of dirt, water, and oil. After inspection, the gears should be coated in a thin layer of engine oil before storage. Store the gears in a clean, dry place.
After cleaning the gears, carefully inspect each gear for cracks, pitting, spalling, scoring, or any other damage to the surface. Refer to the "Damage to the Surface" section for an explanation of these terms. The inspection of the gears should be inspected by using a magnifying glass and a strong light source. It may be difficult to tell the difference between small scratches and cracks. Cracks can be highlighted by using a dry magnetic particle or a test with a dye penetrant. A gear must be free of cracks to be reusable.
NOTICE |
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It is important that you carefully inspect every tooth of each gear. If you are not sure whether a gear can be reused, the gear should be replaced. Serious problems can result from reusing a gear when it actually falls into the "Do Not Use Again" criteria. These problems can include oil pump failure and major damage to the engine. |
Damage to the Surface
Several types of damage to the surface can occur to the oil pump gears. For example, there can be pitting, spalling, and scoring on the gear teeth. Pitting is the result of high contact stresses and the rolling or sliding action of mating teeth. Pitting of a gear tooth can result in failure from fatigue on a surface or below the surface.
There are two types of pitting: There is initial pitting and there is destructive pitting. Initial pitting occurs during the break-in period and initial pitting is not considered to be harmful. Initial pitting does not progress to the stage of destructive pitting. The initial pitting will stop once the gear has been sufficiently broken in. Gears that show signs of initial pitting can be reused in the pump.
Destructive pitting normally occurs after a long period of operation that is combined with high contact stresses. High stress concentrations on the face of the tooth of the gear produce destructive pitting. Then, complete breakdown of the gear tooth can occur quickly. Gears that are showing signs of destructive pitting should not be reused.
Spalling is failure by fatigue from below the surface. Spalling can be the final stages of destructive pitting, or spalling can occur without pitting. Spalling occurs when small cracks from fatigue build-up under the surface of the tooth. An area can be weakened enough to flake off pieces of the face of the tooth. Once spalling begins, spalling will quickly progress to the complete fracture of the tooth. Pump gears that are showing signs of spalling should not be reused.
Scoring results from metal-to-metal contact between mating gears. Scoring looks like vertical scratches on the tip of the tooth. Scoring may also appear in the area of the root of the gear. The sliding action of the teeth of the gears is greatest at the area of the root of the gear.
NOTICE |
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Gears with any crack (regardless of size), any destructive pitting, and/or spalling can cause oil pump and engine damage and are not acceptable in engine oil pumps. If you see any evidence of the above damage to the gear, do not use again. |
Reconditioning
Some gears with minor damage to the surface can be used again after the damaged area has been corrected. Only use a stone for sharpening and oil to correct damage to the surface. Never use a grinder or a power tool for polishing.
If you recondition a gear, remove only raised metal from the tooth surface. Never try to remove pitting or any other damage below surface level.
Visual Inspection of Oil Pump Bearings
Illustration 24 shows normal or acceptable wear on an oil pump bearing. The bearing in Illustration 24 should be replaced as part of a rebuild, but has no concern as a wear pattern of potential failure.
Illustration 24 | g03413637 |
This bearing shows normal wear. Replace as part of a rebuild. |
Oversized Bearings are Available for Reconditioning of Engine Oil Pumps and Scavenge Oil Pumps
Caterpillar Reman is using oversized bearings to salvage the housings and covers of engine oil pumps and scavenge oil pumps for 3500 Engines.
The remanufactured engine oil pumps and the scavenge oil pumps that may use the new oversized 227-4147 Sleeve Bearing are listed in the Table 13below.
Remanufactured Engine Oil Pumps and Scavenge Oil Pumps that Use the 227-4147 Sleeve Bearing | |
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Part Number | Description |
Engine Oil Pump | |
Engine Oil Pump | |
Engine Oil Pump | |
Gear Pump | |
Gear Pump | |
Gear Pump |
The new 227-4147 Sleeve Bearing is being used in remanufacturing when the original 1W-6005 Sleeve Bearing cannot fit properly. If an enlarged bore is found during remanufacturing, the bore is machined to accommodate the outer diameter of an oversized bearing. The outer diameter of the oversized bearing is
Specifications for Measurement
3400 Engine Oil Pump
Illustration 25 | g06305700 |
Specifications for Reusability for 3400 Engine Oil Pump Components.(1) | |||||||
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Item | Description | Part Number
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Part Number
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Part Number
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Minimum | Maximum | Minimum | Maximum | Minimum | Maximum | ||
(A) | Length of gears for the oil pump. | |
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Depth of bores for gears for the oil pump. | |
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(B) | Diameter of gear shafts | |
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Bore in bearings for the gear shafts after assembly | |
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Bore in oil pump body for bearings | |
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(D) | Distance from the end of the idler shaft of the pump to the gear face. | |
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(E) | Distance from the end of the pump drive shaft to the gear face. | |
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(F) | Depth of installation for bearings in cover | |
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(G) | Depth of installation of bearings in body | |
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(1) | Oil pump shafts are not reusable. |
3500 Engine Oil Pump
Illustration 26 | g06305708 |
Illustration 27 | g06305710 |
Illustration 28 | g06305711 |
Diameter of installed bushing |
Illustration 29 | g06305712 |
Diameter of bore for bushing |
Illustration 30 | g06305713 |
Protrusion of the dowel |
Illustration 31 | g06305714 |
Depth of installed bushing in cover |
Illustration 32 | g06305715 |
Depth of installed bushing in housing |
Specifications for Reusability for 3500 Engine Oil Pump Components. | |||||||||
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Item | Description | Part Number
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Part Number
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Part Number
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Part Number
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Maximum | Minimum | Maximum | Minimum | Maximum | Minimum | Maximum | Minimum | ||
(A) | Length of gears for the oil pump. | |
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(A2) | Depth of bores for gears for the oil pump. | |
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(B) | Diameter of gear shafts | |
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(B1) | Bore in bearings for the gear shafts after assembly | |
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(B2) | Bore in oil pump body for bearings | |
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(C) | Distance of the extension of the dowels from the cover | |
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(D) | Distance from the end of the idler shaft of the pump to the gear face. | |
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(E) | Distance from the end of the pump drive shaft to the gear face. | |
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(F) | Depth of installation for bearings in cover | |
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(G) | Depth of installation of bearings in body | |
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(H) | Spring for pressure relief valve | Part Number
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Part Number
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Part Number
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Part Number
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Length under test force | |
N/A | |
N/A | |
N/A | |
N/A | |
Test force. | |
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Free length after the test. | |
N/A | |
N/A | |
N/A | |
N/A | |
Outside diameter | |
N/A | |
N/A | |
N/A | |
N/A | |
(J) | Diameter of valve spool | |
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(K) | Position bearing junction from the centerline through the bearing bores to an angle of 45 ± 15 degrees. (1) | 60 degrees | 30 degrees | 60 degrees | 30 degrees | 60 degrees | 30 degrees | 60 degrees | 30 degrees |
(1) | The junction must be within the minimum and maximum tolerances. |
C175 Engine Oil Pump
Illustration 33 | g06305700 |
Specifications for Reusability for C175 Engine Oil Pump Components
For C175-20 machine applications, the drive side of the |
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A | Length of gears | |
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B | Diameter of gear shafts | |
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Bore in bearings for the gear shafts after assembly | |
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Bore in oil pump body for bearings | |
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C | Distance of the extension of the dowels from the cover | |
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D | Distance from the end of the idler shaft of the pump to the gear face | |
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E | Distance from the end of the pump drive shaft to the gear face | |
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F | Depth of installation for bearings in cover | |
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G | Depth of bearings in body | |
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(1) | For part number |
Inspection of Oil Pump Drive Shaft within
Before reusing oil pump drive shaft use these illustrations to help identify if the shaft that may be used again. These illustrations cannot guarantee that any individual shaft can be reused. There is always some risk of failure. Experience and careful inspection is the best guideline for proper reusing the shaft.
Illustration 34 | g06312173 |
Tooth wear pattern is shown in this illustration with a slight step. Step is barely felt when your nail runs along the surface. Wear pattern appears normal. USE THIS PART AGAIN |
Illustration 35 | g06312175 |
The illustration shows tooth wear pattern. Wear pattern appears normal. USE THIS PART AGAIN |
Illustration 36 | g06312183 |
The end of the tooth has been rounded off on both ends. DO NOT USE THIS PART AGAIN |
Illustration 37 | g06312189 |
The illustration shows uneven wear pattern. DO NOT USE THIS PART AGAIN |
Illustration 38 | g06312190 |
The illustration shows extreme uneven wear pattern. DO NOT USE THIS PART AGAIN |
Assembly Procedure of Oil Pump
The following steps are for the assembly of the oil pump.
Illustration 39 | g06305701 |
For the correct placement of the junction of the sleeve bearing in the pump body assembly, refer to Table 15 for specifications. |
- Use 1P-0510 Driver to install a sleeve bearing (6) into the pump body assembly. Refer to illustration 30. Drive the bearings into the body until the bearings measure
1.5 ± 0.5 mm (0.06 ± 0.02 inch) below the face of the gear bore. Refer to item (G) in Table 15. Check the inside diameter (ID) of the bearings after installation. The ID must be31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) . Refer to item (B) in Table 15. - Heat the gears to a maximum temperature of
316° C (600° F) . - Install the gears on the idler shaft assembly (4) until the gears measure
34.0 ± 0.5 mm (1.34 ± 0.02 inch) from the end of the idler shaft to the gear face. Refer to item (D) in table 15. Install the gear on drive shaft assembly (9) until the gear measures47.0 ± 0.5 mm (1.85 ± 0.02 inch) from the end of the drive shaft to the gear face. - Make sure that both hollow dowels (3) are installed in the cover assembly so the dowels extend
6.0 ± 1.0 mm (0.24 ± 0.04 inch) above the surface of pump cover assembly (1). Refer to item (E) in Table 15.Show/hide tableIllustration 40 g06305702 Placement of junction of the sleeve bearing in the pump cover assembly. Refer to Table 15 for specifications. - Use 1P-0510 Driver to install the sleeve bearings (2) into the pump cover assembly with the junction of the bearings in the correct position (K) in Illustration 39. Drive the bearings into the cover until the bearings measure
1.5 ± 0.5 mm (0.06 ± 0.02 inch) below the face of the pump cover. Refer to item (F) in Table 15. - Put the pump cover assembly in position. Then bolt the cover assembly to the body assembly. Wipe the spool for the pressure relief valve (7) with clean engine oil. Install the spool (7), the spring (8), and the gasket. Bolt the cover for the pressure relief valve (10) to the body assembly.
Note: During the installation of the sleeve bearings, the alignment of the bearing junction should be 45 ± 15° from the centerline of the bearing bores. Refer to specification (K) that is shown in Table 15 and illustration 30 and 39.
Specifications for Measurement of the C175 Oil Scavenge Pump
Illustration 41 | g06305704 |
Specifications for Reusability for C175 Engine Oil Scavenge Pump Components(1) | |||
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Item | Name | Part Number
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Minimum | Maximum | ||
A | Length of gears | |
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Depth of bores for gears | |
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B | Diameter of gear shafts | |
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Bore in bearings for the gear shafts after assembly | |
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Bore in oil pump body for bearings | |
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C | Distance of the extension of the dowels from the cover | |
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D | Distance from the end of the idler shaft of the pump to the gear face | |
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E | Distance from the end of the pump drive shaft to the gear face | |
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F | Depth of installation for bearings in cover | |
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G | Depth of bearings in body | |
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(1) | Oil pump shafts are not reusable. |
Note: Oil pump shafts are currently not reusable.
Assembly Procedure for C175 Oil Scavenge Pump
Illustration 42 | g06305706 |
(A) ( B) Split in the Cap Bearings
(C) ( D) Split in the Body Bearings |
During the installation of the sleeve bearings, the split in the bearings should be 30° from the centerline of the bearing bores, as shown. Use 1P-0510 Driver to install a sleeve bearing (6). Be sure to install the bearings to the correct depth.
C175 Pressure Regulator and Pressure Relief Valve
The pressure regulator and pressure relief valve are one combined assembly on C175 engines. The pressure regulator on the C175 engines monitors main engine oil galley pressure and maintains oil pressure independent of engine speed. The relief valve relieves the system if there happens to be a pressure spike.
Thermal Spray Procedures for Oil Pump Shaft on D348, D398, G398, D399 Engines
Illustration 43 | g03049898 |
Part Number | Finish Size |
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Part Description
Base Metal | Alloy Steel |
Hardness |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear |
Metco Equipment Type | 6P-II |
Metco Material | 447 Grind 453 |
Metco Sealer | 185 |
Finished Thickness | As required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | N/A |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | A J Siphon |
Rotation/Traverse Device | Lathe |
Rotation/Traverse Speed | |
Surface Preparation Method | Grit Blast |
Finishing Method | Grind |
Grinding Equipment Type | Cylindrical grinder |
Recommended Wheel | Si Carbide 46 J or K |
Other Equipment Type | Polisher |
Media Recommendation | 400 Grit Emery |
Remarks |
Flame Spray Process (6P) | Procedure | Check List |
Clean Part | Steam clean or vapor degrease | |
Undercut | N/A | |
Chamfer | Sharp edges - 45° x |
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Remove Oxide | N/A | |
Clean Spray Area | N/A | |
Mask for Blast | Use metal mask or duct tape (Protect keyway with brass key slightly above finish diameter. Remove brass key after grinding.) | |
Blast Equipment | Suction blast cabinet | |
Grit Type and Size | METCOLITE C | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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Remove Blast Mask | If metal used, leave on - if not, remove | |
Mask for Spray | Tape and paint with Anti-Bond | |
Spray Equipment Type | 6P | |
Auxiliary Cooling | A J Siphon | |
Nozzle | 6P7C-K "K" Nozzle | |
Air Capacity/Pressure | 6P-3 Cool side out - |
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Oxygen Pressure | |
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Oxygen Flow | |
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Fuel Gas Pressure | |
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Fuel Gas Flow | |
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Carrier Gas Pressure | |
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Carrier Gas Flow | |
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Spray Rate/Build Up | |
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Gun to Work Distance | |
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Rotation Speed of Part | |
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Traverse Rate of Gun | |
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Gun Fixturing Method | Hand held | |
Top Coat/Thickness | As required | |
Finishing Equipment | Cylindrical grinder | |
Depth of Rough Cut | Plunge grind to |
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Depth of Finish Cut | Dress wheel and traverse to finish size | |
Additional Finish Method | Polish with 400 grit emery if necessary |
Thermal Spray Procedures for 3500 Engine Oil Pump
Illustration 44 | g03083182 |
Note: Face E Flatness |
3500 Engine - Oil Pump Cover | |||
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Diameter (A) | Length (B) | Length (C) | Angle (D) |
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30° ± 1° |
Illustration 45 | g03335028 |
3500 Engine - Oil Pump Body | |||
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Model | Length (A) | Length (B) | Diameter (C) |
3508, 3508B | |
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3512, 3516, 3524B | |
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3512, 3516, 3516B, 3524B | |
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Part Description
Base Metal | Cover: Gray Iron Casting
Body: Ductile Iron Casting |
Hardness | - |
Arc Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Cavitation Erosion |
Arc Spray Equipment Type | SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU |
Wire | TAFA 30T Wire Top Coat, TAFA 75B Wire Bond Coat |
Finish Thickness | As Required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | Filtered shop air |
Rotation/Traverse Speed | |
Surface Preparation Method | Undercut and Grit blast
If the entire surface is to receive an arc spray coating, some shops prefer to undercut or pre-grind the entire surface. This allows for a recommended minimum |
Machining Method | Machine or Grind |
Recommended Cutting Tool | ISCAR DNMG 432TFIC507 |
Blast Media Recommendation | Pressure Type Only (Aluminum Oxide Grit) |
Finishing Equipment Type | Horizontal or Vertical Boring Machine |
Grinding Equipment | Surface Grinder |
Recommended Abrasive | Norton 23A30E12VBEP or equivalent |
Remarks | A low spot repair should not be considered unless at least |
Arc Spray | Procedure | Check List | ||
Clean Part | Degrease in hot caustic solution | |||
Undercut | If the entire surface is to receive an arc spray coating, some shops prefer to undercut or pre-grind the entire surface. This allows for a recommended minimum |
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Remove Oxide | Use fiber flap brush or Clean/strip disc or glass bead | |||
Clean Spray Area | Commercial degreaser | |||
Mask for Grit Blast | Duct Tape, metal shield, or rubber | |||
Grit Blast Equipment | Pressure type only | |||
Grit Type and Size | 20 mesh aluminum oxide | |||
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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Remove Blast Mask | Remove mask material, make sure that surface is clean | |||
Mask for Metal Spray | Casting relief areas, bolt holes, dowel pin holes and bearing bases can be masked with Metco Anti-Bond, blue layout dye, silicon rubber, bulk ceramic fiber, or a combination of these materials. | |||
Metal Spray Equipment Type | Smart Arc by Oerlikon Metco | TAFA | ||
Consumable (Bondcoat) | TAFA 75B | TAFA 75B | ||
Clamp Pressure | |
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Air Jets/Pressure | |
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Arc Load Volts | 30V | 30V | ||
Amps | 125 Amps | 150 Amps | ||
Gun to Work Distance (Standoff) | |
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Spray Rate/Bond Pass | |
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Consumable (Topcoat) | TAFA 30T | TAFA 30T | ||
Clamp Pressure | |
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Air Jets/Pressure | |
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Arc Load Volts | 31V | 31V | ||
Amps | 150 Amps | 175 Amps | ||
Gun to Work Distance (Standoff) | |
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Spray Rate/Build Up | |
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Traverse Rate of Gun | |
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Gun Fixturing Method | Machine mount or hand held | |||
Finishing Equipment | Surface Grinder or Milling Machine | |||
Part/Cutter Rotation Roughing | Grind - Refer to wheel specifications
Machine - |
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Part/Cutter Rotation Finishing | Grind - Refer to wheel specifications
Machine - |
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Coolant | Oil base synthetic - 40:1 ratio | |||
Traverse Speed | Grind - Refer to wheel specifications
Machine - |
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Depth of Rough Cut | Grind - Machine - |
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Depth of Finish Cut | Grind - Machine - |
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Additional Finish Method | Grind - Coating should be ground back to base on edges where possible |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Cavitation Erosion |
Oerlikon Metco Equipment Type | 6P-II by Oerlikon Metco |
Oerlikon Metco Material | Metco 453 |
Finish Thickness | As Required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Speed | |
Rotation Speed | |
Surface Preparation Method | Undercut and Grit blast
If the entire surface is to be built up, you may choose to undercut or pre-grind the entire area. This allows for a recommended minimum |
Finishing Method | Machine or Grind |
Grinding Equipment Type | Surface Grinder |
Recommended Wheel | Norton 23A 30E12VBEP or SGL abrasive H5A24F13-VKP |
Machining Equipment Type | Horizontal or Vertical Boring Machine |
Recommended Cutter Grade | C-2, 883 Carboloy, or equivalent |
Media Recommendation | Metcolite "C" or equivalent |
Remarks | A low spot repair should not be considered unless at least |
Flame Spray Process (6P) | Procedure | Check List |
Clean Part | Degrease in hot caustic solution | |
Undercut | If the entire surface is to be built up, you may choose to undercut or pre-grind the entire area. This allows for a recommended minimum |
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Remove Oxide | Use fiber flap brush, Clean/strip disc | |
Clean Spray Area | Metco cleaning solvent or equivalent | |
Mask for Grit Blast | Duct Tape, metal shield, or rubber | |
Grit Blast Equipment | Pressure type only | |
Grit Type and Size | Metcolite "C" or equivalent | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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Remove Blast Mask | Remove mask, make sure that surface is clean | |
Mask for Metal Spray | Casting relief areas, bolt holes, dowel pin holes and bearing bases can be masked with Metco Anti-Bond, blue layout dye, silicon rubber, bulk ceramic fiber, or a combination of these materials. | |
Metal Spray Equipment Type | 6P-II Hand Held Thermo Spray System by Oerlikon Metco | |
Auxiliary Cooling | If desired | |
Nozzle | 6P-C7A-K "K" Nozzle | |
Air Capacity/Pressure | 6P-3/Cooling Air |
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Oxygen Pressure | |
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Oxygen Flow | |
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Fuel Gas Pressure | |
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Fuel Gas Flow | |
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Carrier Gas Pressure | |
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Carrier Gas Flow | |
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Spray Rate/Build Up | |
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Gun to Work Distance | |
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Traverse Rate of Gun | |
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Gun Fixturing Method | Machine mount or hand held | |
Top Coat/Thickness | |
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Finishing Equipment | Surface Grinder or Milling Machine | |
Part/Cutter Rotation | Grind - Refer to wheel specifications
Machine - |
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Traverse Speed (Rough Cut) | Grind - Refer to wheel specifications
Milling - |
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Traverse Speed (Finish Cut) | Grind - Refer to wheel specifications
Milling - |
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Depth of Rough Cut | Grind - Milling - |
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Depth of Finish Cut | Grind - Milling - |
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Additional Finish Method | Grind - Sparkout (Coating should be ground back to base on edges where possible)
Milling - none |
Thermal Spray Procedures for Oil Pump Manifold
Illustration 46 | g03072137 |
Illustration 47 | g03339409 |
Part Number | Dimension |
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3P-0365 | |
Part Description
Base Metal | Gray Iron |
Hardness | - |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear occurring around oil ports |
Mating Part Contact Area & Material | Gear |
Metco Equipment Type | 6P-II |
Metco Material | 452 or 453 |
Metco Sealer | 185 |
Finished Thickness | As Required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Device | Lathe or turntable |
Rotation/Traverse Speed | |
Surface Preparation Method | Undercut and Grit Blast |
Finishing Method | Machine |
Recommended Cutter Grade | 883 Carboloy or equivalent |
Other Equipment Type | Polish |
Media Recommendation | Emery |
Flame Spray Process (6P) | Procedure | Check List |
Clean Part | Degrease in hot caustic solution | |
Remove Oxide | Clean/strip disc or fiber flap brush | |
Mask for Blast | Duct Tape, metal mask, or rubber plugs | |
Blast Equipment | Pressure | |
Grit Type and Size | 25/40 steel angular grit | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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Mask for Spray | Antibond | |
Spray Equipment Type | 6P-II | |
Nozzle | 6P-C7-K "K" Nozzle | |
Air Capacity/Pressure | 6P-3/Cooling Air |
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Oxygen Pressure | |
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Oxygen Flow | |
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Fuel Gas Pressure | |
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Fuel Gas Flow | |
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Carrier Gas Pressure | |
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Carrier Gas Flow | |
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Spray Rate/Build Up | |
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Gun to Work Distance | |
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Rotation Speed of Part (RPM) | 200 RPM | |
Rotation Speed of Part (SFPM) | |
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Traverse Rate of Gun (SFPM) | |
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Gun Fixturing Method | Machine mount | |
Top Coat/Thickness | |
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Finishing Equipment | Lathe | |
Part/Cutter Rotation (SFPM) | |
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Traverse Speed | |
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Depth of Rough Cut | |
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Depth of Finish Cut | |
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Additional Finish Method | If desired, emery polish |
Thermal Spray Procedures for Gear Shafts for Gear Pumps
Illustration 48 | g03078976 |
Dimensions | |
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A | |
B | |
C | |
D | |
E | |
F | |
G | |
H | |
Part Description
Base Metal | 1018 or 4118 |
Hardness | 50 Rc |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear, bearing failure |
Mating Part Contact Area & Material | Bearing |
Metco Equipment Type | Metco 6P-II |
Metco Material | 453 |
Finished Thickness | As Required |
Finishing Allowance | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Device | Lathe |
Rotation/Traverse Speed | |
Surface Preparation Method | Undercut and Grit blast |
Finishing Method | Machine |
Machining Equipment Type | Lathe |
Recommended Cutter Grade | C2-883 Carboloy or equivalent |
Flame Spray Process (6P) | Procedure | Check List |
Clean Part | Degrease in hot caustic solution | |
Undercut | To "tru-up" surface | |
Remove Oxide | Use fiber flap brush; Clean/strip disc | |
Mask for Blast | Duct Tape | |
Blast Equipment | Pressure type only | |
Grit Type and Size | 25/40 steel angular grit | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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Mask for Spray | Antibond or blue layout dye | |
Spray Equipment Type | 6PH-II Thermo Spray System | |
Auxiliary Cooling | If desired | |
Nozzle | 6P-C7A-K "K" Nozzle | |
Air Capacity/Pressure | 6P-3/Cooling Air |
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Oxygen Pressure | |
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Oxygen Flow | |
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Fuel Gas Pressure | |
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Fuel Gas Flow | |
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Carrier Gas Pressure | |
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Carrier Gas Flow | |
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Spray Rate/Build Up | |
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Gun to Work Distance | |
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Rotation Speed of Part (RPM) | RPM varies depending on shaft diameter | |
Rotation Speed of Part (SFPM) | |
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Traverse Rate of Gun (SFPM) | |
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Gun Fixturing Method | Hand Held or Machine Mount | |
Top Coat/Thickness | |
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Finishing Equipment | Lathe | |
Part/Cutter Rotation (SFPM) | |
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Traverse Speed | |
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Depth of Rough Cut | |
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Depth of Finish Cut | |
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Additional Finish Method | Emery for desired polish |
Storage Procedure
Proper protection of the individual parts within the oil pump, oil pump assemblies, and front housings from corrosion is important. Corrosion will start in as little as one hour after the individual parts within the oil pump, oil pump assemblies and front housings has been cleaned.
When the individual parts within the oil pump, oil pump assemblies and front housings will not be inspected for one hour or less the individual parts within the oil pump, oil pump assemblies and front housings should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The individual parts within the oil pump, oil pump assemblies, and front housings should be individually wrapped to prevent contamination, and the individual parts within the oil pump, oil pump assemblies, and front housings should be stored in a protected area to avoid damage. See Illustration 49.
When the individual parts within the oil pump, oil pump assemblies and front housings will not be inspected in two days or more the individual parts within the oil pump, oil pump assemblies and front housings should be coated with a rust or corrosion inhibitor or coated with clean engine oil and the individual parts within the oil pump, oil pump assemblies and front housings should be individually wrapped. The wrapped individual parts within the oil pump, oil pump assemblies, and front housings should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the individual parts within the oil pump, oil pump assemblies, and front housings. See Illustration 50.
Refer to SEHS9031, "Special Instruction""Storage Procedure for Caterpillar Products" for more information on storage of components.
Illustration 49 | g06278538 |
Example of protection for a component that is stored for a shorter term |
Illustration 50 | g06278539 |
Example of protection for a component that is stored for a longer term |