1/30/24, 3:28 PM SIS 2.

Reuse and Salvage for 3044, 3046, 3064, 3066, 3400, 3500, and C175 Engine Oil Pumps {1304, 1315} (SEBF8170-31)

SMCS - 1304, 1315 i09804521

Caterpillar Products
All 3000 Engines

All 3400 Engines

All 3500 Engines
PIP
-
All C175 Engines

202 1046
All G3500 Engines

4 4
Revision History:

12: 01/3 666

/
Table 1

Revision Summary of Changes

31

30
Updated Tables 25 and 26
2
SEB 8:30+ 0
Added oil pump 466-4981 to Table 15.

Added new serial number prefixes for New Product Introduction (NPI).

© 2 F817 03:00
Corrected specifications for C175 Scavenge pump (Diameter of gear shafts, Bore in bearings for the gear shafts after assembly, and Bore in
29
oil pump body for bearings).
28 Added new serial number prefixes for New Product Introduction (NPI).
27

Introduction
0 2 0
Added new serial number prefixes for New Product Introduction (NPI) and 12 part numbers.

Cat 4 C
e r
Con illa terpi
p a
© 2023 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.

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

ntia Inc
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

l Ye .
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.

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

Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair options or modifications to reuse and salvage
techniques and/or methods.

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

Canceled Part Numbers and Replaced Part Numbers

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

Important Safety Information

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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. Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair
procedures that are used. Ensure that the product will not be damaged or made unsafe by any operation, lubrication, maintenance, or the repair
procedures used.

Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair

on this product, until you have read and understood the
operation, lubrication, maintenance and repair information.

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

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. Refer to
Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

Illustration 2 g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

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

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

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

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

Summary
This guideline should be used for inspecting and measuring the components of a used engine oil pump, reconditioned engine oil pump, and front
housings. Life will vary depending on application, load, lubrication, and environment. 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. Use this guideline to determine whether a part should be reused. Do not install a part
that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

The dimensions and tolerances provided are to return a part / component to specification. The dimensional information alone is not solely used to
condemn a part from reuse. Follow visual inspections and the (X-Ref for "Crack Detection Methods" belongs in this area) section for further guidance.

References
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Table 2

References

Media Number Title

"Gear Tooth Inspection"
https://channel1.mediaspace.kaltura.com/media/Gear+Tooth+Inspection/1_5ujdi5zp
Channel1
"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"

Service Advisories, Service Letters, and Technical Service Bulletins

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

Tooling and Equipment

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

Table 3

Required Tooling and Equipment

Part Number Description

— (1) Personal Protective Equipment (PPE)
1P-0510 Driver
1P-3537 Dial Bore Gauge Kit
1S-0258 Soft Face Hammer
6V-2010 Polishing Stone
6V-2012 Depth Micrometer
9A-1593 Surface Texture Comparison Gauge
223-1694 Dead Blow Hammer
263-9070 Steel File
303-9339 Lint Free Shop Towels
383-8887 Dual Scale Feeler Gauge Set
386-3364 Straight Edge Ruler
441-0714 Spring Tester
448-3698 Profilometer
Internal Micrometer Set
473-8688 2-12 inch
or
473-8689 Internal Micrometer Set
50-300 mm

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Outside Electronic Micrometer Set

473-8690
0-4 inch
Outside Electronic Micrometer Set
473-8691
2-6 inch
(1) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.

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 205 kPa
(30 psi) for cleaning purposes.

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.

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

Measurement Requirements

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

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
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

Table 4

Specifications for the Front Housing(1)

3044 and 3046 Engines

Area Dimension
Diameter for the Bore for the Crankshaft Seal 95.03 to 95.08 mm (3.741 to 3.743 inch)
Bore Diameter for the Front Bearing Support for the Camshaft Gear 80.00 to 80.03 mm (3.150 to 3.151 inch)
Bore Diameter for the Support of the Hydraulic Pump Drive Gear(2) 67.988 to 68.018 mm (2.6767 to 2.6779 inch)
(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.

Table 5

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Specifications for Front Housings(1)

3064 and 3066 Engines

Area Dimension
Bore Diameter for the Crankshaft Seal 95.03 to 95.08 mm (3.741 to 3.743 inch)
Bore Diameter for the Water Pump 104.00 to 104.20 mm (4.095 to 4.102 inch)
(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 3 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 4 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 0.500 mm (0.0197 inch), replace the pump
assembly.

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Illustration 5 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 0.200 mm (0.0079 inch), replace the
pump assembly.

Illustration 6 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 0.150 mm (0.0059 inch),
replace the pump assembly.

Illustration 7 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 0.150 mm (0.0059 inch), replace the pump assembly.

Illustration 8 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
0.200 mm (0.0079 inch), replace the bushing or the pump assembly. The diameter for the oil pump bushing in the engine block is 16.000 to 16.018 mm
(0.6299 to 0.6306 inch).

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

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Illustration 9 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 10 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.

Table 6

Sales Model Above (1)

Below (2)

3064 0.020 mm (0.0008 inch) 0.150 mm (0.0059 inch)

3066 0.010 mm (0.0004 inch) 0.150 mm (0.0059 inch)
(1) The end of the gear is above the housing.
(2) The end of the gear is below the housing.

Illustration 11 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
0.100 mm (0.0039 inch). If the clearance exceeds the specifications, replace the gears.

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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".

PIP
-
202 1046
4
12: 01/3 666
/ 4
Illustration 12
(3) Oil Pump Gear
2
SEB 8:30+ 0
g06305639

© 2 F817 03:00
(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 0.100 to 0.350 mm (0.0039 to 0.0138 inch). If the distance exceeds the specifications, replace both of the gears. Refer to Table 7 for the overall
diameter of the gear that is part of the shaft.

0
Cat 4 C2 0
Inspect the teeth of the gears for damage, cracks, or abnormal wear patterns. For more information regarding the wear patterns of gears, refer to

e
Con rpilla aterpi
Guidelines for Reusable Parts and Salvage Operations, SEBF9244 , "Reuse and Salvage for Gear Train and Gear Shafts on Engines".

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Illustration 13 g06305641
llow
(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
0.150 mm (0.0059 inch). Refer to Table 7 and Table 8 to determine the part or parts that are worn. Replace the part or replace the parts that are worn.

Table 7
Specifications for the Oil Pump Drive Gear and Driven Gear
3064 and 3066 Engines

Part Dimension
Shaft Diameter 19.947 to 19.960 mm (0.7853 to 0.7858 inch)
Overall Diameter of the Gear 51.815 to 51.955 mm (2.0400 to 2.0455 inch)

Table 8
Specifications for the Front Housing and Cover for the Oil Pump
3064 and 3066 Engines

Part Dimension
Housing Inside Diameter (1)
20.00 to 20.21 mm (0.787 to 0.796 inch)
Cover Inside Diameter
Diameter of the Bore for the Spindle 20.00 mm (0.787 inch)
0.04 to 0.07 mm (0.002 to 0.003 inch)
Clearance Between The Housing And The Shaft Service Limit
0.150 mm (0.0059 inch)
(1) This diameter is for the drive and driven gears.

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Illustration 14 g06305646
(5) Spindle
(8) Idler Gear Bushing

Measure the inside diameter of idler gear bushing (8). If the measurement does not fall within 24.939 to 24.960 mm (0.9818 to 0.9827 inch), replace the
gear assembly.

Measure the diameter of spindle (5) in the area of the rotation of the gear. If the measurement does not fall within 25.000 to 25.021 mm
(0.9843 to 0.9851 inch), replace the spindle. The diameter for the spindle that presses into the housing is 20.05 to 20.07 mm (0.789 to 0.790 inch).

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 15 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.

Table 9
Specifications for the Idler Gear Shaft
3044 and 3046 Engines
Dimension Reference To The Figure (1)
39.975 to 39.991 mm (1.5738 to 1.5744 inch) 14
30.00 to 30.10 mm (1.181 to 1.185 inch) 15
51.50 to 52.10 mm (2.028 to 2.051 inch) 16
35.060 to 35.076 mm (1.3803 to 1.3809 inch) 17
(1) Reference figure 15 for the areas for measuring.

Table 10
Specifications for the Bore for the Idler Gear Shaft
3044 and 3046 Engines
Dimension Reference To The Figure
35.006 to 35.030 mm (1.3782 to 1.3791 inch) N/A

Table 11
Specifications for the Idler Gear Shaft
3064 and 3066 Engines
Dimension Reference To The Figure (1)
39.955 to 39.971 mm (1.5730 to 1.5737 inch) 14

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26.00 to 26.10 mm (1.024 to 1.028 inch) 15

47.50 to 48.10 mm (1.870 to 1.893 inch) 16
35.076 to 35.080 mm (1.3809 to 1.3811 inch) 17
(1) Reference figure 15 for the areas for measuring.

Table 12
Specifications for the Bore for the Idler Gear Shaft
3064 and 3066 Engines
Dimension Reference To The Figure
34.991 to 34.955 mm (1.3780 to 1.3762 inch) N/A

Nomenclature
3400 Engine Oil Pump

Illustration 16 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

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Illustration 17 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 18 g06305691
(1) Body Assembly
(2) Sleeve Bearing
(3) Input Drive Shaft
(4) Cover Assembly
(5) Sleeve Bearing
(6) Shaft Assembly

Visual Inspection
Spool for Pressure Relief Valve

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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 19 g03680564
Use the 441-0714 Spring Tester to test the springs.
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
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 20 g06305699

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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 12.70 mm
(0.500 inch) in diameter and 3.175 mm (0.1250 inch) in depth.

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
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
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.

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Visual Inspection of Oil Pump Bearings

Illustration 21 shows normal or acceptable wear on an oil pump bearing. The bearing in Illustration 21 should be replaced as part of a rebuild, but has no
concern as a wear pattern of potential failure.

Illustration 21 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.

Table 13

Remanufactured Engine Oil Pumps and Scavenge Oil Pumps that Use the 227-4147 Sleeve Bearing

Part Number Description

0R-2561 Engine Oil Pump
0R-3230 Engine Oil Pump
0R-4345 Engine Oil Pump
0R-3233 Gear Pump
0R-3860 Gear Pump
0R-9250 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 35.189 ± 0.015 mm (1.3854 ± 0.0006 inch). The new oversized bearing has the same inner diameter as the original bearing. The bores of a
remanufactured pump could have a combination of the new 227-4147 Sleeve Bearing and of the original 1W-6005 Sleeve Bearing. Refer to Table 15 for
standard bore sizes.

Specifications for Measurement

3400 Engine Oil Pump

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Illustration 22 g06305700

Table 14

Specifications for Reusability for 3400 Engine Oil Pump Components.(1)

Part Number
Part Number
Part Number 161-4110
116-1980
4N-0735 161-4112
Location Description 520-2923
4N-8735 161-4113
520-2924
198-1508

Minimum Maximum Minimum Maximum Minimum Maximum

Length of gears for the oil 57.133 mm 57.183 mm 79.350 mm 79.400 mm 139.075 mm 140.025 mm
pump. (2.24933 inch) (2.25129 inch) (3.12401 inch) (3.12598 inch) (5.47 inch) (5.51 inch)
A
Depth of bores for gears 57.265 mm 57.305 mm 79.482 mm 79.522 mm 140.107 mm 140.147 mm
for the oil pump. (2.25452 inch) (2.25610 inch) (3.12921 inch) (3.13078 inch) (5.516 inch) (5.517 inch)
22.212 mm 22.222 mm 22.212 mm 22.222 mm 22.212 mm 22.222 mm
Diameter of gear shafts
(0.875 inch) (0.875 inch) (0.875 inch) (0.875 inch) (0.875 inch) (0.875 inch)
Bore in bearings for the 22.312 mm 22.322 mm 22.312 mm 22.322 mm 22.312 mm 22.322 mm
B
gear shafts after assembly (0.878 inch) (0.878 inch) (0.878 inch) (0.878 inch) (0.878 inch) (0.878 inch)
Bore in oil pump body for 26.957 mm 26.973 mm 26.957 mm 26.973 mm 26.957 mm 26.973 mm
bearings (1.06 inch) (1.06 inch) (1.06 inch) (1.06 inch) (1.06 inch) (1.06 inch)
Distance from the end of
36.25 mm 36.75 mm 36.25 mm 36.75 mm 36.25 mm 36.75 mm
D the idler shaft of the pump
(1.42 inch) (1.44 inch) (1.42 inch) (1.44 inch) (1.42 inch) (1.44 inch)
to the gear face.
Distance from the end of
52.75 mm 53.25 mm 52.75 mm 53.25 mm 52.75 mm 53.25 mm
E the pump drive shaft to the
(2.07 inch) (2.09 inch) (2.07 inch) (2.09 inch) (2.07 inch) (2.09 inch)
gear face.
Depth of installation for 1.0 mm 2.0 mm 1.0 mm 2.0 mm 1.0 mm 2.0 mm
F
bearings in cover (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch)
Depth of installation of 0.05 mm 0.55 mm 0.05 mm 0.55 mm 0.05 mm 0.55 mm
G
bearings in body (0.002 inch) (0.022 inch) (0.002 inch) (0.022 inch) (0.002 inch) (0.022 inch)
(1) Oil pump shafts are not reusable.

3500 Engine Oil Pump

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PIP
-
202 1046
4
12: 01/3 666
/ 4
2
SEB 8:30+ 0
© 2 F817 03:00
0 0
Illustration 23 g06305708

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

Illustration 24 g06305710

Illustration 25 g06305711
Diameter of installed bushing

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Illustration 26 g06305712
Diameter of bore for bushing

Illustration 27 g06305713
Protrusion of the dowel

Illustration 28 g06305714
Depth of installed bushing in cover

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Illustration 29 g06305715
Depth of installed bushing in housing
Table 15

Specifications for Reusability for 3500 Engine Oil Pump Components.

Part Number
Part Number Part Number
231-5127
Part Number 4P-5638 106-9872
395-4207
Location Description 7W-0053 245-6771 273-1587
441-0039
372-5733 466-4981
485-4728

Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum

Length of gears
54.015 mm 53.985 mm 84.015 mm 83.985 mm 110.015 mm 109.985 mm 110.015 mm 109.985 mm
A for the oil
(2.1266 inch) (2.1254 inch) (3.3077 inch) (3.3065 inch) (4.3313 inch) (4.3301 inch) (4.3313 inch) (4.3301 inch)
pump.
Depth of bores
54.170 mm 54.130 mm 84.170 mm 84.130 mm 110.170 mm 110.130 mm 110.170 mm 110.130 mm
A2 for gears for
(2.1327 inch) (2.1311 inch) (3.3138 inch) (3.3122 inch) (4.3374 inch) (4.3358 inch) (4.3374 inch) (4.3358 inch)
the oil pump.
Diameter of 31.750 mm 31.734 mm 31.750 mm 31.734 mm 31.750 mm 31.734 mm 31.750 mm 31.734 mm
B
gear shafts (1.2500 inch) (1.2494 inch) (1.2500 inch) (1.2494 inch) (1.2500 inch) (1.2494 inch) (1.2500 inch) (1.2494 inch)
Bore in
bearings for the 31.824 mm 31.798 mm 31.824 mm 31.798 mm 31.824 mm 31.798 mm 31.824 mm 31.798 mm
B1
gear shafts (1.2529 inch) (1.2519 inch) (1.2529 inch) (1.2519 inch) (1.2529 inch) (1.2519 inch) (1.2529 inch) (1.2519 inch)
after assembly
Bore in oil
34.950 mm 34.920 mm 34.950 mm 34.920 mm 34.950 mm 34.920 mm 34.950 mm 34.920 mm
B2 pump body for
(1.3760 inch) (1.3748 inch) (1.3760 inch) (1.3748 inch) (1.3760 inch) (1.3748 inch) (1.3760 inch) (1.3748 inch)
bearings
Distance of the
extension of 7.0 mm 5.0 mm 7.0 mm 5.0 mm 7.0 mm 5.0 mm 7.0 mm 5.0 mm
C
the dowels (0.28 inch) (0.20 inch) (0.28 inch) (0.20 inch) (0.28 inch) (0.20 inch) (0.28 inch) (0.20 inch)
from the cover
Distance from
the end of the
34.5 mm 33.5 mm 34.5 mm 33.5 mm 34.5 mm 33.5 mm 34.5 mm 33.5 mm
D idler shaft of
(1.36 inch) (1.32 inch) (1.36 inch) (1.32 inch) (1.36 inch) (1.32 inch) (1.36 inch) (1.32 inch)
the pump to the
gear face.
Distance from
the end of the
47.5 mm 46.5 mm 47.5 mm 46.5 mm 47.5 mm 46.5 mm 47.5 mm 46.5 mm
E pump drive
(1.87 inch) (1.83 inch) (1.87 inch) (1.83 inch) (1.87 inch) (1.83 inch) (1.87 inch) (1.83 inch)
shaft to the
gear face.
Depth of
installation for 2.0 mm 1.0 mm 2.0 mm 1.0 mm 2.0 mm 1.0 mm 2.0 mm 1.0 mm
F
bearings in (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch)
cover

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Depth of
installation of 2.0 mm 1.0 mm 2.0 mm 1.0 mm 2.0 mm 1.0 mm 2.0 mm 1.0 mm
G
bearings in (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch)
body
Spring for
Part Number Part Number Part Number Part Number
pressure relief
2S-2760 2S-2760 107-7175 417-2406
valve
Length under 117.9 mm 117.9 mm 107.16 mm 102 mm
N/A N/A N/A N/A
test force (4.64 inch) (4.64 inch) (4.219 inch) (4.016 inch)
H 517 N 463 N 517 N 463 N 576 N 536 N 762 N 690 N
Test force.
(116.2 lb) (104.1 lb) (116.2 lb) (104.1 lb) (129.5 lb) (120.5 lb) (171.3 lb) (155.1 lb)
Free length 152.9 mm 152.9 mm 144.4 mm 144.4 mm
N/A N/A N/A N/A
after the test. (6.02 in) (6.02 in) (5.69 in) (5.69 in)
Outside 27.00 mm 27.00 mm 27.00 mm 27.00 mm
N/A N/A N/A N/A
diameter (1.063 inch) (1.063 inch) (1.063 inch) (1.063 inch)
Diameter of 35.637 mm 35.611 mm 35.637 mm 35.611 mm 35.637 mm 35.611 mm 35.637 mm 35.611 mm
J
valve spool (1.4030 inch) (1.4020 inch) (1.4030 inch) (1.4020 inch) (1.4030 inch) (1.4020 inch) (1.4030 inch) (1.4020 inch)
Position
bearing
junction from
the centerline
K through the 60 degrees 30 degrees 60 degrees 30 degrees 60 degrees 30 degrees 60 degrees 30 degrees
bearing bores
to an angle of
45 ± 15
degrees. (1)
(1) The junction must be within the minimum and maximum tolerances.

C175 Engine Oil Pump

Illustration 30 g06305700

Table 16
Specifications for Reusability for C175 Engine Oil Pump Components
For C175-20 machine applications, the drive side of the 341-2500 and 527-6204 oil pumps are not reusable. The 532-8727 oil pum
be reused at overhaul. The driven side is reusable in all pumps, given that it meets other reuse criteria.
Par
Part Number Part Number Part Number Part Number 296
340-9259 340-9261 341-2503 416-9858 341
Location Description
527

Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum Min

Length of 121.907 mm 121.933 mm 137.147 mm 137.173 mm 150.407 mm 150.433 mm 91.293 mm 91.303 mm 10
gears (4.7995 inch) (4.8005 inch) (5.3995 inch) (5.4005 inch) (5.9215 inch) (5.9225 inch) (3.59421 inch) (3.59460 inch) (4.
A Depth of
122.035 mm 122.075 mm 137.28 mm 137.32 mm 150.535 mm 150.575 mm 91.48 mm 91.52 mm 10
bores for
(4.8045 inch) (4.8060 inch) (5.4047 inch) (5.4063 inch) (5.9265 inch) (5.9281 inch) (3.60157 inch) (3.60314 inch) (4.2
gears

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Diameter of 50.788 mm 50.798 mm 50.788 mm 50.798 mm 50.788 mm 50.798 mm 59.923 mm 59.933 mm 59

gear shafts (1.9995 inch) (1.9999 inch) (1.9995 inch) (1.9999 inch) (1.9995 inch) (1.9999 inch) (2.35917 inch) (2.35956 inch) (2.3
Bore in
bearings for
50.878 mm 50.958 mm 50.878 mm 50.958 mm 50.878 mm 50.958 mm 60.006 mm 60.072 mm 60
the gear
B (2.0030 inch) (2.0062 inch) (2.0030 inch) (2.0062 inch) (2.0030 inch) (2.0062 inch) (2.36244 inch) (2.36503 inch) (2.3
shafts after
assembly
Bore in oil
55.647 mm 55.663 mm 55.647 mm 55.663 mm 55.647 mm 55.663 mm 66.042 mm 66.058 mm 66
pump body for
(2.1908 inch) (2.1914 inch) (2.1908 inch) (2.1914 inch) (2.1908 inch) (2.1914 inch) (2.60007 inch) (2.60070 inch) (2.6
bearings
Distance of
the extension
7.5 mm 8.5 mm 7.5 mm 8.5 mm 7.5 mm 8.5 mm 7.5 mm 8.5 mm
C of the dowels
(0.30 inch) (0.34 inch) (0.30 inch) (0.34 inch) (0.30 inch) (0.34 inch) (0.30 inch) (0.34 inch) (0
from the
cover
Distance from
the end of the
41 mm 42 mm 41 mm 42 mm 41 mm 42 mm 43 mm 44 mm
D idler shaft of
(1.6 inch) (1.6 inch) (1.6 inch) (1.6 inch) (1.6 inch) (1.6 inch) (1.69291 inch) (1.73228 inch) (1.6
the pump to
the gear face
Distance from
7
the end of the
91.35 mm 91.45 mm 91.35 mm 91.45 mm 91.35 mm 91.45 mm 114.40 mm 115.4 mm (2.7
E pump drive
(3.596 inch) (3.600 inch) (3.596 inch) (3.600 inch) (3.596 inch) (3.600 inch) (4.50393 inch) (4.54330 inch) 11
shaft to the
(4.5
gear face
Depth of
installation for 1 mm 2 mm 1 mm 2 mm 1 mm 2 mm 1 mm 2 mm
F
bearings in (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0.04 inch) (0.08 inch) (0
cover
Depth of
1.25 mm 1.75 mm 1.25 mm 1.75 mm 1.25 mm 1.75 mm 1.25 mm 1.75 mm
G bearings in
(0.049 inch) (0.069 inch) (0.049 inch) (0.069 inch) (0.049 inch) (0.069 inch) (0.049 inch) (0.069 inch) (0
body
(1) For part number 296-5590.

Inspection of Oil Pump Drive Shaft within 532-8727 Oil Pumps

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 31 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

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Illustration 32 g06312175
The illustration shows tooth wear pattern. Wear pattern appears normal.
USE THIS PART AGAIN

Illustration 33 g06312183
The end of the tooth has been rounded off on both ends.
DO NOT USE THIS PART AGAIN

Illustration 34 g06312189
The illustration shows uneven wear pattern.
DO NOT USE THIS PART AGAIN

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Illustration 35 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 36 g06305701
For the correct placement of the junction of the sleeve bearing in the pump body assembly, refer to Table 15 for specifications.

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 27 and 36.

1. Use 1P-0510 Driver to install a sleeve bearing (6) into the pump body assembly. Refer to illustration 27. 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 be 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch). Refer to item (B) in Table 15.

2. Heat the gears to a maximum temperature of 316° C (600° F).

3. 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 measures 47.0 ± 0.5 mm (1.85 ± 0.02 inch) from the end
of the drive shaft to the gear face.

4. 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.

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Illustration 37 g06305702
Placement of junction of the sleeve bearing in the pump cover assembly. Refer to Table 15 for specifications.
5. 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 36. 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.

6. 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.

Specifications for Measurement of the C175 Oil Scavenge Pump

Illustration 38 g06305704
Table 17

Specifications for Reusability for C175 Engine Oil Scavenge Pump Components (1)
Part Number
342-7800
Location Description 524-1308
Minimum Maximum

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Length of gears 147.307 mm (5.7995 inch) 147.333 mm (5.8005 inch)

A
Depth of bores for gears 147.440 mm (5.8047 inch) 147.480 mm (5.8063 inch)
Diameter of gear shafts 50.787 mm (1.9995 inch) 50.803 mm (2.0001 inch)
B Bore in bearings for the gear shafts after assembly 50.870 mm (2.0028 inch) 50.958 mm (2.0062 inch)
Bore in oil pump body for bearings 55.647 mm (2.1908 inch) 55.663 mm (2.1915 inch)
C Distance of the extension of the dowels from the cover 7.500 mm (0.2953 inch) 8.500 mm (0.3346 inch)
D Distance from the end of the idler shaft of the pump to the gear face 41.100 mm (1.6181 inch) 42.100 mm (1.65748 inch)
E Distance from the end of the pump drive shaft to the gear face 41.100 mm (1.6181 inch) 42.100 mm (1.65748 inch)
F Depth of installation for bearings in cover 1.000 mm (0.0394 inch) 2.000 mm (0.0787 inch)
G Depth of bearings in body 1.000 mm (0.0394 inch) 2.000 mm (0.0787 inch)
(1) Oil pump shafts are not reusable.

Note: Oil pump shafts are currently not reusable.

Assembly Procedure for C175 Oil Scavenge Pump

Illustration 39 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

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Illustration 40 g03049898

Table 18

Part Number Finish Size

PIP
-
4L-6758 31.699 ± 0.008 mm (1.2480 ± 0.0003 inch)

Part Description
202 1046
Table 19

12: 4 / 0 4 666
1
Base Metal Alloy Steel
Hardness

2 / 3
Flame Spray Equipment and Procedure
SEB :30+ 0
8
© 2 F817 03:00
Table 20
Maximum Surface Texture 0.51 µm (20.07874 µinch)
Reason for Spraying Wear

Cat 024 C 0
Metco Equipment Type 6P-II
Metco Material 447 Grind 453

e a
Metco Sealer 185
Finished Thickness
Finishing Allowance r
Con illa terpi
p As required
0.51 mm (0.020 inch)
Spray Angle

fide r: llar
90°

Inc
Substrate Pre-Heat Temperature N/A

ntia
Substrate Temperature During Spraying Not to Exceed 204° C (400° F)

.
l Ye
Auxiliary Cooling A J Siphon
Rotation/Traverse Device Lathe
Rotation/Traverse Speed
Surface Preparation Method
Finishing Method
llow
91.4 SMPM (300.00 SFPM)
Grit Blast
Grind
Grinding Equipment Type Cylindrical grinder
Recommended Wheel Si Carbide 46 J or K
Other Equipment Type Polisher
Media Recommendation 400 Grit Emery
Remarks

Table 21
Check
Flame Spray Process (6P) Procedure
List
Clean Part Steam clean or vapor degrease
Undercut N/A
Chamfer Sharp edges - 45° x 0.79 mm (0.031 inch)
Remove Oxide N/A
Clean Spray Area N/A
Use metal mask or duct tape (Protect keyway with brass key slightly above finish diameter. Remove brass
Mask for Blast
key after grinding.)
Blast Equipment Suction blast cabinet
Grit Type and Size METCOLITE C
Blast Air Pressure 621 kPa (90.0 psi)
Blast Nozzle to Work
51 mm (2.0 inch)
Distance
Remove Blast Mask If metal used, leave on - if not, remove
Mask for Spray Tape and paint with Anti-Bond

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Spray Equipment Type 6P

Auxiliary Cooling A J Siphon
Nozzle 6P7C-K "K" Nozzle
Air Capacity/Pressure 6P-3 Cool side out - 170 kPa (25.0 psi)
Oxygen Pressure 210 kPa (30.0 psi)
Oxygen Flow 1190 L/h (42.0 cfh)
Fuel Gas Pressure 100 kPa (15.0 psi)
Fuel Gas Flow 1415 L/h (50.0 cfh)
Carrier Gas Pressure 380 kPa (55.0 psi)
Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build Up 5.5 kg (12.00 lb) per hour 0.10 - 0.15 mm (0.004 - 0.006 inch) per pass
Gun to Work Distance 229 mm (9.0 inch)
Rotation Speed of Part 91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun 15 SMPM (50.00 SFPM) minimum
Gun Fixturing Method Hand held
Top Coat/Thickness As required
Finishing Equipment Cylindrical grinder
Depth of Rough Cut Plunge grind to 0.13 mm (0.005 inch) oversize
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 41 g03083182
Note: Face E Flatness 0.025 mm (0.001 inch)
Table 22

3500 Engine - Oil Pump Cover

Diameter A Length B Length C Angle D

34.935 ± 0.015 mm (1.3754 ± 0.0006 inch) 34.00 ± 1.0 mm (1.3386 ± 0.0394 inch) 1.0 ± 0.25 mm (0.0394 ± 0.0098 inch) 30° ± 1°

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Illustration 42 g03335028

Table 23

3500 Engine - Oil Pump Body

Model Length A Length B Diameter C

54.15 ± 0.02 mm
3508, 3508B
163.0 ± 0.5 mm (2.13189 ± 0.00079 inch)
(6.41731 ± 0.01969 inch) 84.15 ± 0.02 mm 71.33 ± 0.025 mm
3512, 3516, 3524B
(3.31299 ± 0.00079 inch) (2.80826 ± 0.00098 inch)
3512, 3516, 3516B, 189.0 ± 0.5 mm 110.15 ± 0.02 mm
3524B (7.44093 ± 0.01969 inch) (4.33661 ± 0.00079 inch)

Part Description
Table 24

Cover: Gray Iron Casting

Base Metal
Body: Ductile Iron Casting
Hardness -

Arc Spray Equipment and Procedure

Table 25

Maximum Surface Texture 1.6 µm (62.99213µinch)

Reason for Spraying Cavitation Erosion
Arc Spray Equipment Type SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU
Top Coat
TAFA 30T Wire, Metco 8230, or equivalent
Wire
Bond Coat
TAFA 75B, Metco 8400, or equivalent
Finish Thickness As Required
Finishing Allowance 0.51 to 0.64 mm (0.020 to 0.025 inch) per side
Spray Angle 90°
Substrate Pre-Heat Temperature 66° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During
148° C (300° F)
Spraying Not to Exceed
Auxiliary Cooling Filtered shop air
Rotation/Traverse Speed 11.0 SMPM (40.00 SFPM)
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.
Surface Preparation Method
This allows for a recommended minimum 0.25 mm (0.010 inch) coating, produces an even coating, reduce both cost
and finish machining time.

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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
A low spot repair should not be considered unless at least 0.05 to 0.08 mm (0.002 to 0.003 inch) can be removed
Remarks
from the cover thickness during grinding.

Table 26

Check
Arc Spray Procedure
List
Clean Part Degrease in hot caustic solution
If the entire surface is to receive an arc spray coating, some shops prefer to undercut or pre-grind the entire surface.
Undercut This allows for a recommended minimum 0.25 mm (0.010 inch) coating, produces an even coating, reduce both cost
and finish machining time.
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 690 kPa (100.0 psi)
Blast Nozzle to Work
51 to 150 mm (2.0 to 6.0 inch)
Distance
Remove Blast Mask Remove mask material, make sure that surface is clean
Casting relief areas, bolt holes, dowel pin holes and bearing bases can be masked with Metco Anti-Bond, blue layout
Mask for Metal Spray
dye, silicon rubber, bulk ceramic fiber, or a combination of these materials.
Metal Spray
Smart Arc by Oerlikon Metco TAFA
Equipment Type
Consumable
Metco 8400 or equivalent TAFA 75B or equivalent
(Bondcoat)
Clamp Pressure 275 kPa (40 psi)
Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 30V 30V
Amps 125 Amps 150 Amps
Gun to Work
128 mm (5.0 inch) 128 mm (5.0 inch)
Distance (Standoff)
Spray Rate/Bond
0.038 mm (0.0015 inch)/pass 0.038 mm (0.0015 inch)/pass
Pass
Consumable
Metco 8230 or equivalent TAFA 30T or equivalent
(Topcoat)
Clamp Pressure 275 kPa (40 psi)
Air Jets/Pressure 415 kPa (60 psi) 415 kPa (60 psi)
Arc Load Volts 31V 31V
Amps 150 Amps 175 Amps
Gun to Work
166 mm (6.5 inch) 166 mm (6.5 inch)
Distance (Standoff)
Spray Rate/Build
0.058 mm (0.0023 inch)/pass 0.058 mm (0.0023 inch)/pass
Up
Traverse Rate of
11.0 SMPM (40.00 SFPM)
Gun
Gun Fixturing Method Machine mount or hand held
Finishing Equipment Surface Grinder or Milling Machine
Part/Cutter Rotation Grind - Refer to wheel specifications
Roughing Machine - 50.0 SMPM (150.00 SFPM)
Part/Cutter Rotation Grind - Refer to wheel specifications
Finishing Machine - 75.0 SMPM (250.00 SFPM)

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Coolant Oil base synthetic - 40:1 ratio

Grind - Refer to wheel specifications
Traverse Speed
Machine - 0.30 mm (0.012 inch) per revolution
Grind - 0.04 mm (0.0015 inch)
Depth of Rough Cut
Machine - 0.51 mm (0.020 inch)
Grind - 0.01 mm (0.0005 inch)
Depth of Finish Cut
Machine - 0.25 mm (0.010 inch)
Additional Finish
Grind - Coating should be ground back to base on edges where possible
Method

Flame Spray Equipment and Procedure

Table 27

Maximum Surface Texture 1.6 µm (62.99213µinch)

Reason for Spraying Cavitation Erosion
Oerlikon Metco Equipment
6P-II by Oerlikon Metco
Type
Oerlikon Metco Material Metco 453
Finish Thickness As Required
Finishing Allowance 0.51 to 0.64 mm (0.020 to 0.025 inch) per side
Spray Angle 90°
Substrate Pre-Heat
66° C (150° F) Do not direct flame on area to be sprayed
Temperature
Substrate Temperature During
148° C (300° F)
Spraying Not to Exceed
Auxiliary Cooling If desired
Rotation/Traverse Speed 15.3 SMPM (50.00 SFPM)
Rotation Speed 91.4 SMPM (300.00 SFPM)
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
Surface Preparation Method
recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating
and can reduce both cost and finish machining time.
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
A low spot repair should not be considered unless at least 0.05 to 0.08 mm (0.002 to 0.003 inch) can be removed from
Remarks
the cover thickness during grinding or unless the repair is to be finished by hand to blend the coating.

Table 28

Flame Spray Process Check

Procedure
(6P) List
Clean Part Degrease in hot caustic solution
If the entire surface is to be built up, you may choose to undercut or pre-grind the entire area. This allows for a
Undercut recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating
and can reduce both cost and finish machining time.
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 310 kPa (45.0 psi)
Blast Nozzle to Work
50 mm (2.0 inch)
Distance
Remove Blast Mask Remove mask, make sure that surface is clean

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Casting relief areas, bolt holes, dowel pin holes and bearing bases can be masked with Metco Anti-Bond, blue layout
Mask for Metal Spray
dye, silicon rubber, bulk ceramic fiber, or a combination of these materials.
Metal Spray Equipment
6P-II Hand Held Thermo Spray System by Oerlikon Metco
Type
Auxiliary Cooling If desired
Nozzle 6P-C7A-K "K" Nozzle
Air Capacity/Pressure 6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure 210 kPa (30.0 psi)
Oxygen Flow 1190 L/h (42.0 cfh)
Fuel Gas Pressure 100 kPa (15.0 psi)
Fuel Gas Flow 1415 L/h (50.0 cfh)
Carrier Gas Pressure 380 kPa (55.0 psi)
Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build Up 5.5 kg (12 lb) per hour or 90 gr (3.2 oz) per min
Gun to Work Distance 178 mm (7.0 inch)
Traverse Rate of Gun 15.3 SMPM (50.00 SFPM)
Gun Fixturing Method Machine mount or hand held
Top Coat/Thickness 0.10 to 0.15 mm (0.004 to 0.006 inch) per pass
Finishing Equipment Surface Grinder or Milling Machine
Grind - Refer to wheel specifications
Part/Cutter Rotation
Machine - 45.7 SMPM (150.00 SFPM)
Traverse Speed Grind - Refer to wheel specifications
(Rough Cut) Milling - 203 mm (8.0 inch) per min.
Traverse Speed (Finish Grind - Refer to wheel specifications
Cut) Milling - 38.1 to 0.51 mm (1.50 to 2.00 inch) per min
Grind - 0.03 to 0.05 mm (0.001 to 0.002 inch)
Depth of Rough Cut
Milling - 0.38 to 0.51 mm (0.015 to 0.020 inch)
Grind - 0.03 mm (0.001 inch)
Depth of Finish Cut
Milling - 0.25 to 0.38 mm (0.010 to 0.015 inch)
Additional Finish Grind - Sparkout (Coating should be ground back to base on edges where possible)
Method Milling - none

Thermal Spray Procedures for Oil Pump Manifold

Illustration 43 g03072137

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Illustration 44 g03339409

Table 29

Part Number Dimension

3P-0365 44.7 ± 0.25 mm (1.76 ± 0.010 inch)

Part Description
Table 30
Base Metal Gray Iron
Hardness -

Flame Spray Equipment and Procedure

Table 31

Maximum Surface Texture 1.6 µm (62.99213µinch)

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 0.51 to 0.64 mm (0.020 to 0.025 inch) per side
Spray Angle 90°
Substrate Pre-Heat Temperature 66° C (150° F)
Substrate Temperature During Spraying Not to Exceed 148° C (300° F)
Auxiliary Cooling If desired
Rotation/Traverse Device Lathe or turntable
Rotation/Traverse Speed 8.7 to 10.5 SMPM (250.00 to 300.00 SFPM)
Surface Preparation Method Undercut and Grit Blast
Finishing Method Machine
Recommended Cutter Grade 883 Carboloy or equivalent
Other Equipment Type Polish
Media Recommendation Emery

Table 32

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

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Blast Air Pressure 620 kPa (90.0 psi)

Blast Nozzle to Work Distance 50 mm (2.0 inch)
Mask for Spray Antibond
Spray Equipment Type 6P-II
Nozzle 6P-C7-K "K" Nozzle
Air Capacity/Pressure 6P-3/Cooling Air 140 kPa (20.0 psi)
Oxygen Pressure 210 kPa (30.0 psi)
Oxygen Flow 1190 L/h (42.0 cfh)
Fuel Gas Pressure 100 kPa (15.0 psi)
Fuel Gas Flow 1415 L/h (50.0 cfh)
Carrier Gas Pressure 380 kPa (55.0 psi)
Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build Up 5.5 kg (12 lb) per hour or 90 g (3.2 oz) per min
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed of Part (RPM) 200 RPM
Rotation Speed of Part (SFPM) 91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun (SFPM) 15.24 SMPM (50.000 SFPM)
Gun Fixturing Method Machine mount
Top Coat/Thickness 0.10 to 0.15 mm (0.004 to 0.006 inch) per pass
Finishing Equipment Lathe
Part/Cutter Rotation (SFPM) 10.5 SMPM (300.00 SFPM)
Traverse Speed 0.05 to 0.10 mm (0.002 to 0.004 inch) per revolution
Depth of Rough Cut 0.38 to 0.51 mm (0.015 to 0.020 inch) per side
Depth of Finish Cut 0.25 to 0.38 mm (0.010 to 0.015 inch) per side
Additional Finish Method If desired, emery polish

Thermal Spray Procedures for Gear Shafts for Gear Pumps

Illustration 45 g03078976

Table 33

Dimensions
A 15.667 ± 0.008 mm (0.6168 ± 0.0003 inch)
B 15.867 ± 0.008 mm (0.6247 ± 0.0003 inch)
C 18.820 ± 0.008 mm (0.7410 ± 0.0003 inch)
D 18.852 ± 0.005 mm (0.7422 ± 0.0002 inch)

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E
PIP
22.217 ± 0.005 mm (0.8747 ± 0.0002 inch)

-
F 31.742 ± 0.005 mm (1.2497 ± 0.0002 inch)

202 1046
G 41.232 ± 0.005 mm (1.6233 ± 0.0002 inch)
H 50.240 ± 0.08 mm (1.978 ± 0.003 inch)

Table 34
4
12: 01/3 666
/ 4
2
Part No. Dimension Callout Part No. Dimension Callout Part No. Dimension Callout Part No. Dimension Callout

SEB 8:30+ 0
9F-6665 C 9M-8178 F 115-0639 F 7S-6973 F
9F-6666 C 9M-8281 F 114-4680 F 7S-7601 A
7G-1014 E 9M-8282 F 8P-6848 F 7S-8596 F

© 2 F817 03:00
7G-1015 E 1P-0634 F 8P-6849 F 7S-8628 F
7G-1057 E 1P-0980 F 8P-8165 F 7S-8657 F

Cat 024 C 0
7G-2243 F 1P-0981 F 8P-8211 E 8S-0678 F
7G-2244 F 1P-1989 E 8P-8212 E 8S-0679 F

e
7G-2539 E 1P-1990 E 8P-9733 F 8S-3377 E
7G-2540
7G-3207
E
G
1P-2186
1P-4230 r
Con illa terpi
p a E
F
9P-3463
9P-3464
B
B
8S-3442
8S-3443
F
F
7G-3208
7G-5710
G
E
fide r:
1P-6746
1P-8184
E
E llar 9P-7473
9P-7474
E
E
8S-9163
9S-4386
F
F
7G-6784 F 1P-9654

ntia E
Inc1S-0088 F 9S-6586 A

.
7G-9721 G 1P-9655 E 1S-3728 F 9S-6789 F
7G-9722 G 2P-1966
l Ye
F 2S-0151 F 9S-9385 F

llow
9G-0635 G 2P-5768 F 2S-0152 F 9S-9931 F
9G-0637 G 2P-5774 F 2S-0167 F 3T-3699 F
9G-2805 E 2P-9319 F 2S-0168 F 3T-3701 F
9G-7411 G 2P-9321 F 2S-0691 F 3T-5672 F
9G-7412 G 2P-9332 E 2S-3610 F 3T-5674 F
9G-9544 F 3P-0256 F 2S-3611 F 3T-6989 F
9G-9545 F 3P-0258 F 2S-5841 F 3T-6990 F
9G-9900 F 3P-0377 F 2S-7918 E 3T-7880 F
9G-9901 F 3P-0877 F 2S-7919 E 3T-7882 F
1H-6361 A 3P-0881 F 2S-8574 F 3T-8085 F
5H-3298 D 3P-4575 F 2S-8575 F 3T-8086 F
5H-3417 D 3P-4576 F 3S-2613 G 3T-8093 F
5H-3470 D 116-4625 F 3S-2614 G 3T-8927 F
9H-5761 F 3P-4629 E 3S-4380 F 3T-9904 F
9H-5775 F 3P-4850 F 3S-4382 F 3T-9905 F
3K-2345 H 3P-4851 F 3S-4383 E 6T-1540 F
2M-3400 F 3P-7619 F 3S-4384 E 6T-1541 F
4M-0503 F 3P-7620 F 3S-7254 E 6T-1542 F
4M-0504 F 3P-7783 F 3S-8799 A 6T-3931 F
7M-6595 F 3P-7784 F 4S-5978 F 6T-3932 F
8M-1480 B 3P-7790 F 4S-6777 F 6T-4263 F
8M-1481 B 3P-7791 F 4S-6778 F 6T-4264 F
8M-2586 F 3P-7959 G 4S-8659 E 6T-4416 E
8M-2592 F 3P-7960 G 4S-9000 E 6T-4417 E
8M-6144 F 3P-8019 F 4S-9001 E 6T-4844 F
8M-9563 F 3P-8881 F 5S-1598 E 7T-4330 F
9M-1166 F 3P-8883 F 5S-1599 E 7T-5656 F
9M-1721 F 6P-4965 F 5S-3682 E 7T-5657 F

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9M-1722 F 6P-4966 F 5S-3683 E 7T-6751 F

9M-1723 F 6P-7357 F 5S-4383 F 7T-6752 F
9M-2200 F 6P-8328 F 7S-2903 E 9W-3270 F
9M-4356 F 8P-4547 F 7S-3882 F 9W-3713 F
9M-4382 F 115-0640 F 7S-4488 F 9W-9018 F
9M-5452 F 114-4682 F 7S-4579 F 6Y-0186 F
9M-8177 F 8P-4548 F 7S-6972 F 6Y-0187 F

Part Description
Table 35

Base Metal 1018 or 4118

Hardness 50 Rc

Flame Spray Equipment and Procedure

Table 36
Maximum Surface Texture 0.51 µm (20.07874 µinch)
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 0.51 mm (0.020 inch) to 0.64 mm (0.025 inch) per side
Spray Angle 90°
Substrate Pre-Heat Temperature 66°C (150°F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed 148°C (300°F)
Auxiliary Cooling If desired
Rotation/Traverse Device Lathe
Rotation/Traverse Speed 91.4 SMPM (300.00 SFPM)
Surface Preparation Method Undercut and Grit blast
Finishing Method Machine
Machining Equipment Type Lathe
Recommended Cutter Grade C2-883 Carboloy or equivalent

Table 37

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 620 kPa (90.0 psi)
Blast Nozzle to Work Distance 50 mm (2.0 inch)
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 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure 210 kPa (30.0 psi)
Oxygen Flow 1190 L/h (42.0 cfh)

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Fuel Gas Pressure 100 kPa (15.0 psi)

Fuel Gas Flow 1415 L/h (50.0 cfh)
Carrier Gas Pressure 380 kPa (55.0 psi)
Carrier Gas Flow 1050 L/h (37.0 cfh)
Spray Rate/Build Up 5.5 kg (12 lb) per hour or 90 g (3.2 oz) per min
Gun to Work Distance 230 mm (9.0 inch)
Rotation Speed of Part (RPM) RPM varies depending on shaft diameter
Rotation Speed of Part (SFPM) 91.4 SMPM (300.00 SFPM)
Traverse Rate of Gun (SFPM) 15.24 SMPM (50.000 SFPM)
Gun Fixturing Method Hand Held or Machine Mount
Top Coat/Thickness 0.10 to 0.15 mm (0.004 to 0.006 inch) per pass
Finishing Equipment Lathe
Part/Cutter Rotation (SFPM) 91.4 SMPM (300.00 SFPM)
Traverse Speed 0.05 to 0.10 mm (0.002 to 0.004 inch) per revolution
Depth of Rough Cut 0.38 to 0.51 mm (0.015 to 0.020 inch) per side
Depth of Finish Cut 0.25 to 0.38 mm (0.010 to 0.015 inch) per side
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 46.

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 47.

Refer to SEHS9031 , "Special Instruction""Storage Procedure for Caterpillar Products" for more information on storage of components.

Illustration 46 g06278538
Example of protection for a component that is stored for a shorter term

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Illustration 47 g06278539
Example of protection for a component that is stored for a longer term

PIP-10464666
2024/01/30
12:28:21+03:00
i03211300
© 2024 Caterpillar Inc.
Caterpillar:
Confidential Yellow

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