- Caterpillar Products
- All Cat Engines
Introduction
Revision | Summary of Changes in SEBF8418 |
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22 | Added new serial number prefixes. |
20–21 | Combined information from SEBF2126, SEBF2128, SEBF2157, SEBF8058, SEBF8110, SEBF8276, SEBF8740, SEBF9042, SEBF9267 added 9 part numbers and repaired 84 pixelated illustrations. |
19 | Added new serial number prefixes. |
© 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 may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
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 provides the most current information available on the disassembly, inspection, reuse, and assembly of water pump components. Engines. Many times, the installation of new water pump components is not necessary during an engine overhaul. Normally, used water pump components that are acceptable according to this guideline can give the same performance as new parts until the next overhaul. Use this guideline as the only source of reference to determine the reusability of the water pump.
To determine if water pump components can be used again, use the inspection specifications given in this guideline. Some components that do not meet the inspection specifications can be reconditioned to like new condition. Never reuse a component that does not meet all the reusability specifications.
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 | |
---|---|
Media Number | Title |
Channel1 | "Why Reuse and Salvage Parts" |
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z | |
SEBF9238 | Reuse and Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning Components" |
SEBF9240 | Reuse and Salvage Guidelines, "Fundamentals of Flame Spray for Reconditioning Components" |
SEHS9031 | Special Instructions , "Storage Procedure for Caterpillar Products" |
, SEPD0390 | Special Instructions, "Handling Instructions For Water Pumps" |
Tooling and Equipment
NOTICE |
---|
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Tooling and Equipment | |
---|---|
Part Number | Description |
Drive Plate | |
Driver | |
O-Ring Assembly Compound | |
Washers | |
Washers | |
Washers | |
Puller | |
Quick Cure Primer | |
Polishing Stone | |
Polishing Wheel | |
Installation Tool | |
Bolt | |
Polishing Wheel | |
Gasket | |
Retaining Compound | |
Adapter | |
FT-1704 | Impeller Installer |
FT-1732 | Drill Fixture |
KBN-625 | Cogsdill Knurling Tool |
K5-154 | Cogsdill Knurling Tool |
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. |
Nomenclature for C-9 and C9 Engines
Illustration 3 | g06281422 |
C-9 Engine Water Pump Nomenclature (1) Cover (2) Gasket (3) Pump Impeller (4) Seal Assembly (5) Water Pump Housing (6) Plug (7) Water Pump Shaft (8) Drive Pulley |
Nomenclature for 3044, 3046, and 3064 Engines
Illustration 4 | g06281470 |
3044, 3046, and 3064 Engine Water Pump Nomenclature (1) Water Pump Group (2) Flange (3) Shaft (4) Retaining Ring (5) Ball Bearing (6) Impeller (7) Spacer (9) Ball Bearing (10) Washer (11) Seal (13) Pulley |
Nomenclature for 3176 Engines
Illustration 5 | g06281011 |
3176 Engine Water Pump Nomenclature (1) Water Pump Housing (2) Pump Retainer (3) Gear (41 teeth) (4) Ball Bearing (5) Seal (Lip-type) (6) Filter (7) Water Seal Assembly (8) O-ring Seal (9) Pump Impeller (10) Water Pump Shaft (11) Pump Cover |
Nomenclature for 3208 Engines
Illustration 6 | g06280354 |
3208 Front housing nomenclature. (1) Bearing Bore (2) Snap Ring Groove (3) Pulley Face (4) Ears (5) Drain Hole |
Illustration 7 | g06280357 |
3208 Rear housing nomenclature. (6) Pilot Diameter (7) Seal Bore (8) Gasket Face (9) Seal Bore Spot Face |
Jacket Water Pumps
Changes in water pumps over the years have incorporated the following changes:
- Press on impeller vs bolt on impeller
- Ceramic seal vs steel seal
- Pinned seal retainer
- Straight shaft vs tapered
Older Style Water Pumps
Illustration 8 | g02028113 |
Typical example of an older style water pump. (1) Seal Group (2) Water Pump Seal (3) Retainer (4) Impeller (5) Washer (6) Nut (7) Seal - Lip Type (8) Ball (9) Shaft Assembly (10) Washer - Thrust (11) Filter - Foam (12) Plug (13) Identification Plate (14) Housing Assembly |
Current Water Pumps
Current style water pump groups are used on all Commercial Engines and on all Machine Engines. The current water pump groups differ from an older style due to updates in the ring assembly, the seal group, and the shaft assembly. These new components provide the water pump group with increased resistance to damage from shock loads and leaking that typically occur during shipping, handling, and installation.
Illustration 9 | g06280903 |
Typical example of a water pump. (1) Plug - Pipe (2) Seal Lip Type (3) Seal Assembly (4) Seal O-Ring (5) Seal O-Ring (6) Bolt (7) Impeller (8) Adapter (9) Washer - Thrust (10) Bolt - Socket Head (11) Shaft (12) Washer (13) Plug O-Ring (14) Plug Pipe (15) Housing Assembly |
Earlier Water Pumps
Illustration 10 | g02309516 |
Example of an earlier water pump |
Later Water Pumps
Illustration 11 | g02309594 |
Example of a later water pump |
Water Pump Applications for 3600 Engines | ||
---|---|---|
Earlier Pump Part Number | Later Pump Part Number | Pump Type |
Fresh Water | ||
Fresh Water | ||
Sea Water |
Handling Procedure
Correct handling of the water pumps used is necessary critical to prevent damage. Improper handling of the water pumps can cause cracking of the seal face group. Damage to the face seals may cause the water pumps to leak. Relative movement between the shaft and the housing may allow the drive shaft to contact the face seal. If contact occurs, the face seal will be damaged.
To prevent damage to the face seal, follow the proper water pump handling procedures.
- Do NOT move the water pump shaft in respect to the water pump housing.
- Do NOT set the water pump down with the shaft on the ground.
- Do NOT handle the water pump by the shaft.
- Do NOT use a hammer, mount, or other device on the water pump or on the shaft that might cause movement between the shaft and the housing.
Cleaning Procedure
After disassembly, the water pump will need to be cleaned thoroughly prior to inspection. Use the following steps to ensure that the various parts are properly cleaned without damaging the parts.
Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using. |
Housing and Steel Parts
Use a hot detergent spray or place parts in a high-pressure cabinet washer to clean dirt and grease from the housing and impeller. Remove any corrosion or debris with steel shot. If steel shot is unavailable, use glass beads with
Inspect all areas of the housing for cracks. Carefully inspect the flange by the bolt holes and the sealing surfaces.
Inspect the areas of the housing that contains the seals. Any type of pitting is not allowed in the area that contains the seal. If the area is pitted, the pump could leak.
Shaft
NOTICE |
---|
Do not use glass beads or shot blast to clean the shaft. This will damage the bearing and seal surfaces, making the shaft unusable. |
Clean the shaft with solvent only. Be careful not to damage the bearing and seal surfaces. Light scratches can be removed with a polishing wheel. A 6V-6147 Polishing Wheel or 8T-7748 Polishing Wheel can also be used to clean the shaft. Light scratches can be removed with a polishing wheel.
Whenever the water pump is removed from the engine, protect the exposed shaft with the plastic from shipping.
NOTICE |
---|
Do not reuse a shaft that has grooves or wear steps. Also, do not reuse a shaft that has scratches remaining after polishing. |
Impeller
Examine the blades of the impeller for damage and wear. The impeller must pass a visual inspection first followed by a bore specification. Only use the impeller again if it passes both the visual inspection and specification inspection.
Inspect the outside tip of the impeller blades for scratches or erosion. If the tips of the blades show signs of damage, the impeller must be replaced.
Inspect the entire length of each blade for erosion or cracks. If there is any damage to the blades, the impeller must be replaced.
Inspect the seal face for pitting, erosion, or scratches. If there is any damage to the seal face, the impeller must be replaced.
NOTICE |
---|
Do not reuse an impeller that has any visible damage or wear. |
Aluminum Parts
The aluminum parts should be cleaned with a steam pressure washer or a high-pressure cabinet washer with an aluminum-safe solvent. Then remove corrosion and debris with glass beads, 80 to 150 micron (size 10).
Measurement Requirements
NOTICE |
---|
Precise measurements shall be made when the component and measurement equipment are at |
Inspection and Salvage Procedures
After cleaning, a visual inspection helps to identify which parts can be reused and which cannot. The three critical areas of inspection are the housing, the impeller shaft, and the impeller.
Housing for C-9 and C9 Engines
Illustration 12 | g06281439 |
Check seal diameter (D) |
Seal Diameter Specifications for Water Pump Housing for C-9 and C9 Engines | |
---|---|
Item | Dimension |
(D) | |
- Inspect all areas of the housing for cracks. Carefully inspect the flange areas by the bolt holes and the sealing surfaces.
- Check the bearing and seal bores for pitting. Slight pitting in the bearing area is permitted, but not in the seal area.
Housing for 3044, 3046, and 3064 Engines
Illustration 13 | g06281483 |
Housing for 3044, 3046, and 3064 Engines(1) | |
---|---|
Bore Size (D) | Bore Size (E) |
|
|
(1) | The housing is nonserviceable. You must purchase the complete pump assembly if the housing is not reusable. |
Housing for 3176 Engines
Illustration 14 | g06281022 |
Seal Diameters for Housing on 3176 Engines | |
---|---|
Callout | Dimension |
D | |
E | |
- Inspect all areas of the housing for cracks. Carefully inspect the flange areas by the bolt holes and the sealing surfaces.
- Check the bearing and seal bores for pitting. Slight pitting in the bearing area is permitted, but not in the seal area.
- Examine the O-ring groove for pitting, scratches, or other damage. Do not reuse a housing that has a damaged O-ring groove.
Housing for 3208 Engines
Illustration 15 | g06280398 |
Wear step in the housing bore. |
Use again - after the wear step is removed by applying thermal metal spray. For more information, refer to "Thermal Spray Procedures for Water Pump Housing Bore on 3208 Engines".
Illustration 16 | g06280403 |
Pits in the bearing bore. |
Use again
Illustration 17 | g06280414 |
Gouges in the bearing bore. |
Use again - after the raised (high) areas are removed with a half-round file.
Illustration 18 | g06280425 |
Scratches in the bearing bore. |
Use again
Illustration 19 | g06280432 |
Damage to the snap ring groove. |
Use again - after burrs are removed with a 6V-2010 Polishing Stone.
Illustration 20 | g06280435 |
Damage to the pulley face caused by forcing screws. |
Use again
Illustration 21 | g06280438 |
Nick on the edge of the housing. |
Use again - after burrs on the gasket face are removed with a file.
Illustration 22 | g06280444 |
Pits on the gasket face. |
Use again - only if the flat seal length from the pilot diameter to the edge of the housing in any area is more than
Illustration 23 | g06280449 |
Erosion (gradual wear) on the pilot diameter. |
Use again
Illustration 24 | g06280453 |
Pits and scratches on the seal bore spotface. |
Use again
Illustration 25 | g06280455 |
Nicks in the seal bore. |
Use again - after raised material is removed carefully with a half-round file.
Note: Do not use the housing again if the seal length from the front to the rear of the seal bore in any area is less than
Illustration 26 | g06280457 |
Ear broken from the housing. |
Use again - only if there is no damage to the web, and after the ear is welded.
Illustration 27 | g06280460 |
Pit in the seal bore. |
Use again
Note: Do not use the housing again if the seal length from the front to the rear of the seal bore in any area is less than
Housing Salvage Procedure for 3208 Engines
Salvage Broken Ears
A housing with a broken ear, as shown in Illustration 26, can still be used, if the web is not damaged. The salvage procedure is as follows:
- Grind the broken ear(s) flat beyond the hole as shown in Illustration 28.
Show/hide table
Illustration 29 g06280515 Housings in position on the welding table. Two housings are shown in this photo; it is a recommendation that a minimum of two housings be salvaged at one time for maximum efficiency. - Install the housing(s) to the welding table with the broken ear(s) over an aluminum plate, as shown in Illustration 29.
Show/hide table
Illustration 30 g06280521 If two housings are salvaged at one time, weld one ear and then let the weld cool while the other ear is welded. Use a 3/16" low amp electrode for cast iron. - Build up (add layers to) the ear(s) with weld. Let the weld cool between each layer and remove weld slag before each application. See Illustration 30.
Note: Use a good quality welding rod made for cast iron welding with an AWS specification of ENi CI.
Show/hide tableIllustration 31 g06280536 Gasket face of the ear. - Turn the housing(s) over and fill the holes in the gasket face of the ear(s) with weld. See Illustration 31. Correct any cracks with a V-groove filled with weld.
Show/hide table
Illustration 32 g06280541 Follow the outer shape of the 9N-0137 Gasket as a guide to grind the ear to the correct shape. - Grind the gasket face smooth. Use a 9N-0137 Gasket as a guide for the shape of the ear. See Illustration 32.
Show/hide table
Illustration 33 g06280546 Ear and bolt face after grinding. - Grind the ear and bolt face. See Illustration 33.
Show/hide table
Illustration 34 g06280548 The last step: drill a hole in the welded ear. - Use an FT–1732 Drill Fixture and a 10.71 mm (27/6 inch) drill bit to cut a hole in the welded ear.
Illustration 28 | g06280513 |
Ear ground flat beyond the bolt hole. |
Housing for 3500 Engines
Visually inspect the water pump housing, then measure the sealing bores with a dial bore gauge.
Housing Inspection
First perform a visual inspection on the entire housing. Only use the housing again if it passes the visual inspection. Inspect for scratches, cracks, dings, damage, corrosion, and pitting. Some slight pitting in the bearing area is permitted but not in the sealing areas. Next, inspect the O-ring surfaces for nicks and dings. Finally, inspect the threaded holes for damaged or stripped threads.
Housing Specifications
If the water pump has passed the visual inspection, then measure the diameter of the seal bores. Use the housing again only if the measurements meet the specifications.
Illustration 35 | g06280463 |
Typical water pump seal bore locations (A) Oil Seal Bore (B) Water Seal Bore |
Seal Diameters for Housing on 3500 Engines | |
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Callout | Dimension |
A | |
B | |
Earlier Housings
Illustration 36 | g06280896 |
Earlier Housing Dimensions for 3600 Engines | ||
---|---|---|
Number | Description | Measurement |
F | Depth of Bearing from Surface of Pump Housing | |
G | Bearing Bore Diameter | |
Later Housings
Illustration 37 | g06280909 |
Later Housing Dimensions for 3600 Engines | ||
---|---|---|
Number | Description | Measurement |
F | Installation Depth of Bearing | |
G | Installation Depth of Bearing | |
H | Installation Depth of Bearing | |
I | Front Bearing Bore Diameter | |
J | Rear Bearing Bore Diameter | |
Shaft for C-9 and C9 Engines
Illustration 38 | g06281450 |
C-9 and C9 Engine Water Pump Shaft (A) Impeller and water seal diameter (B) Bearing diameter (C) Pulley diameter |
Water Pump Shaft Nomenclature and Specifications for C-9 and C9 Engines | ||
---|---|---|
Item | Description | Dimension |
(A) | Impeller and water seal diameter | |
(B) | Bearing diameter | |
(C) | Pulley diameter | |
Shaft for 3044, 3046, and 3064 Engines
Illustration 39 | g01212524 |
Shaft for 3044, 3046, and 3064 Engines | ||
---|---|---|
Part Number | Diameter (A) | Diameter (B) |
|
|
|
|
|
Illustration 40 | g06281494 |
Flange for 3044, 3046, and 3064 Engines | |
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Part Number | Bore Size (F) |
|
Shaft for 3176 Engines
Illustration 41 | g06281384 |
3176 Engine Water Pump Shaft (A) Bearing and Gear diameter (B) Oil Seal diameter (C) Impeller and Water Seal diameter |
Shaft Dimensions for 3176 Engines | ||
---|---|---|
Number | Description | Measurement |
A | Bearing and Gear diameter | |
B | Oil Seal diameter | |
C | Impeller and Water Seal diameter | |
Nomenclature
Illustration 42 | g06280609 |
3208 Engine Water Pump Shaft (14) Bearing diameter (15) Seal diameter (16) Bearing shoulder (17) Pulley end. |
Illustration 43 | g06280813 |
Remove debris and corrosion from the shaft with a |
NOTICE |
---|
Use the 6V-6147 Polishing Wheel only. Other polishing wheels can remove too much material and damage the shaft. |
Illustration 44 | g06280820 |
Scratch along the length of the seal diameter. |
Use again - only if the scratch can be removed with a 6V-6147 Polishing Wheel.
Illustration 45 | g06280823 |
Groove near the pulley end of the bearing diameter. |
Use again
Illustration 46 | g06280827 |
Wear step along the circumference of the bearing diameter. |
Shaft for 3500 Engines
After cleaning and if necessary polishing dimensional checks of the water pump shaft. Refer to Table 15 for the critical dimensions.
Illustration 47 | g06281548 |
Former style shafts with tapered area. |
The former style shafts as shown in Illustration 47 are not serviceable and must be replaced with a newer style press in shaft. The tapered shaft is easily distinguishable by the tapered area as indicated in Illustration 47. If the former tapered style shaft is discovered, then the water pump can still be salvaged. Currently there are three distinct types of current style shafts, the styles are shown in Illustrations 48,49, and 50.
A current style shaft must replace the tapered shaft. If the impeller is to be salvaged, then the tapered impeller bore must be machined straight. Salvaging the impeller bore can be found in the "Impeller Salvage for 3500 Engines" section within this document.
Illustration 48 | g03444156 |
Illustration 49 | g03487319 |
Illustration 50 | g06281550 |
- Measure the critical diameters. Refer to Illustrations 48,49, and 50 to find the applicable shaft style.
Current style shafts have critical dimensional areas to check. The critical areas are called out in Illustrations 48,49, and 50. Also, refer to Table 15 for the correct diameters related to the applicable shaft. These dimensions are critical to obtain a water tight seal and a friction fit at reassembly.
- Measure runout. Refer to Table 15 for the correct diameters related to the applicable shaft.
Measure runout where referenced in Table 15. A shaft that is out of specifications in runout will potentially damage seals prematurely, create a water leak, and can cause a low hour failure.
Water Pump Shaft Reuse Specifications for 3500 Engines | |||||
---|---|---|---|---|---|
Shaft Part Number | (A) | (B) | (C) | (D)(1) | (E) |
N/A | Diameter
Runout N/A |
Diameter
Runout N/A |
Diameter
Runout |
Diameter
Runout |
|
Diameter
Runout |
Diameter
Runout N/A |
Diameter
Runout N/A |
Diameter
Runout |
Diameter
Runout |
|
N/A | Diameter
Runout N/A |
Diameter
Runout N/A |
Diameter
Runout |
Diameter
Runout |
|
N/A | Diameter
Runout N/A |
Diameter
Runout N/A |
Diameter
Runout |
Diameter
Runout |
|
N/A | Diameter
Runout N/A |
Diameter
Runout N/A |
Diameter
Runout |
Diameter
Runout |
(1) | The oil seal diameter can be machined |
If the water pump shaft still shows signs of light wear or rust after cleaning, polishing, and inspecting, then an attempt can be made to machine the shaft. The oil seal diameter portion is the only section that can be machined undersized. The shaft must be machined using a grinder, do not attempt to machine the shaft with a lathe. If machining the oil seal diameter, ensure that the following criteria are met:
- Use a grinder wheel that can machine the entire surface of the oil seal. A minimum wheel width of
10.50 mm (0.413 inch) is recommended. - Remove as minimal amount of material as necessary to remove the damage to the shaft.
- The shaft can be machined to a minimal diameter
0.025 mm (0.001 inch) undersized. - The surface finish must be within 0.25 to 0.50 microns to be acceptable.
- After machining, the shaft must be polished, cleaned, and measured.
Earlier Shafts
Illustration 51 | g06280918 |
Earlier Shaft Dimensions for 3600 Engines | ||
---|---|---|
Number | Description | Measurement |
A | Width of Groove in Shaft | |
B | Shaft Diameter at Surface of Carbon Seal | |
C | Diameter of Impeller Shaft | |
D | Diameter of Support End of Shaft | |
Illustration 52 | g06280932 |
Earlier Plate Dimensions for 3600 Engines | ||
---|---|---|
Number | Description | Measurement |
E | Width of the Plate | |
Illustration 53 | g06280944 |
Fresh water shaft support |
Illustration 54 | g06280958 |
Sea water shaft support |
Earlier Shaft Support Dimensions for 3600 Engines | ||
Number | Description | Measurement |
I | Depth of Bearing from Surface of Support | |
H | Support Bore Diameter | |
Illustration 55 | g06280960 |
Earlier Shaft End Play Dimension for 3600 Engines | ||
Number | Description | Measurement |
J | End play of Impeller Shaft | to |
Later Shafts
Illustration 56 | g06280921 |
Later Shaft Dimensions for 3600 Engines | ||
---|---|---|
Number | Description | Measurement |
A | Width of Groove in Shaft | |
B | Shaft Diameter at Surface of Carbon Seal | |
C | Diameter of Impeller Shaft | |
D | Diameter of Support End of Shaft | |
Illustration 57 | g06280932 |
Later Shaft Dimensions for 3600 Engines | ||
---|---|---|
Number | Description | Measurement |
E | Width of the Plate | |
Illustration 58 | g06280966 |
Later Shaft End Play Dimension for 3600 Engines | ||
---|---|---|
Number | Description | Measurement |
K | End play of Impeller Shaft | to |
Impeller for C-9 and C9 Engines
Illustration 59 | g02151114 |
Impeller for C-9 and C9 Engines (9) Impeller blades |
- The outside tip of impeller blades (9), should not have any grooves, scratches, or erosion.
- Check the entire length of each impeller blade for erosion or cracks. Damage to the blades cannot be repaired and the impeller must be replaced.
- Use a GO NO/GO plug gauge to check the diameter of the impeller bore. The GO (green) end of the plug gauge should be
15.872 mm (0.62488 inch) in diameter. The NO GO (red) end should be15.885 mm (0.62539 inch) . - If the green end of the gauge does not fit in the impeller bore, the impeller can be used again as is, if it is acceptable according to subsequent visual inspections.
- If the green end of the gauge fits through the impeller bore, check to see if the red end of the gauge fits in the bore.
- If the red end of the gauge fits through the impeller bore, do not use the impeller again.
- If the red end of the gauge does not fit in the bore, refer to the "Impeller Salvage for C-9 and C9 Engines" section.
Impeller Salvage for C-9 and C9 Engines
Bore Salvage
Prior to reassembly, the bore in the impeller must be knurled. The purchase of a special tool is necessary to perform this procedure. Salvaging impellers will only be cost effective when many impellers can be salvaged at the same time.
Illustration 60 | g06280597 |
Cogsdill KBN-625 Knurling Tool. |
The salvage procedure is as follows:
- Turn the adjustment screw of the Cogsdill KBN-625 Knurling Tool. until the distance across the roll is
16.433 mm (0.64697 inch) .Show/hide tableIllustration 61 g06280599 Knurl the bore at approximately 265 rpm 0.254 mm/revolution (265 rpm .010"/revolution). - Knurl the bore at approximately 265 rpm 0.254 mm/revolution (265 rpm .010"/revolution) on a lathe or drill press. Hand feed can be used. Use cutting oil or coolant during the procedure.
- After the knurling procedure, use a plug gauge to check that the bore dimension is correct.
- Before assembly, clean the bore and mating shaft with 6V-1541 Quick Cure Primer and put 9S-3265 Retaining Compound on both parts.
Impeller for 3044, 3046, and 3064 Engines
Illustration 62 | g06281498 |
Impeller for 3044, 3046, and 3064 Engines | |
---|---|
Part Number | Bore Size (C) |
|
|
|
Impeller for 3176 Engine
Illustration 63 | g06281392 |
Impeller (12) Seal face (13) Impeller blades |
- The outside tip of impeller blades (13), should not have any grooves, scratches, or erosion.
- Check the entire length of each impeller blade for erosion or cracks. Damage to the blades cannot be repaired and the impeller must be replaced.
- Inspect seal face (12) for pitting, erosion, and scratches. If there is any damage to the seal face, the impeller must be replaced.
- Use a GO NO/GO plug gauge to check the diameter of the impeller bore. The GO (green) end of the plug gauge should be
15.893 mm (0.62571 inch) in diameter. The NO GO (red) end should be15.985 mm (0.62933 inch) . - If the green end of the gauge does not fit in the impeller bore, the impeller can be used again as is, if it is acceptable according to subsequent visual inspections.
- If the green end of the gauge fits through the impeller bore, check to see if the red end of the gauge fits in the bore.
- If the red end of the gauge fits through the impeller bore, do not use the impeller again.
- If the red end of the gauge does not fit in the bore, refer to the "Impeller Salvage for C-9 and C9 Engines" section.
Impeller Salvage for 3176 Engines
Bore Salvage
Prior to reassembly, the bore in the impeller must be knurled. The purchase of a special tool is necessary to perform this procedure. Salvaging impellers will only be cost effective when many impellers can be salvaged at the same time.
Illustration 64 | g06280597 |
Cogsdill KBN-625 Knurling Tool. |
The salvage procedure is as follows:
- Turn the adjustment screw of the Cogsdill KBN-625 Knurling Tool. until the distance across the roll is
16.433 mm (0.64697 inch) .Show/hide tableIllustration 65 g06280599 Knurl the bore at approximately 265 rpm 0.254 mm/revolution (265 rpm .010"/revolution). - Knurl the bore at approximately 265 rpm 0.254 mm/revolution (265 rpm .010"/revolution) on a lathe or drill press. Hand feed can be used. Use cutting oil or coolant during the procedure.
- After the knurling procedure, use a plug gauge to check that the bore dimension is correct.
Impeller for 3208 Engine
Illustration 66 | g06280553 |
Rear Impeller (10) Shaft Bore (11) Seal Bore (12) Blade (13) Back Face |
Two areas of the impeller must be measured: the bore and the blade.
Illustration 67 | g06280559 |
Check the impeller bore dimension with the green end of the gauge first. |
Use the type of plug gauge that has a gauge at each end to check the diameter of the impeller bore. See Illustration 67. (One end of the plug gauge is green and has a
- If the green end of the gauge does not fit in the impeller bore, the impeller bore can be used again as is, if it is acceptable according to the remainder of the visual inspections.
- If the green end of the gauge does fit through the impeller bore, check to see if the red end of the gauge fits in the bore.
- If the red end of the gauge does fit through the impeller bore, do not use the impeller again.
- If the red end of the gauge does not fit in the bore.
Use a scale to measure the distance from the back face of the impeller to the top of the blade. See Illustration 68. If this distance is more than
Also, measure blade from leading edge to trailing edge. See Illustrations 68 through 69. If this dimension is less than
NOTICE |
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Impellers with blade wear must be installed with an FT–1704 Impeller installer to give acceptable performance. |
Illustration 68 | g06280564 |
Measure the blade height. |
Illustration 69 | g06280567 |
Tip erosion is within the "Use again minimum" dimension. (A) Leading Edge (B) Trailing Edge |
Use again - if the dimension is greater than
Illustration 70 | g06280573 |
Some tip erosion but area of tip is greater than the "Use again minimum" dimension. |
Use again
Illustration 71 | g06280576 |
Tip erosion greater than the "Use again minimum" dimension. |
Do not use again
Illustration 72 | g06280579 |
Wear step on the back face of the impeller. |
Use again
Illustration 73 | g06280581 |
Damage to the shaft bore. |
Use again
Illustration 74 | g06280583 |
Erosion of blades. |
Do not use again
Illustration 75 | g06280587 |
Face damage. |
Do not use again
Illustration 76 | g06280588 |
Porosity. |
Do not use again
Illustration 77 | g06280589 |
Groove in blade tip (C) and back plate wear (D). |
Do not use again
Illustration 78 | g06280591 |
Crack in a blade. |
Do not use again
Illustration 79 | g06280593 |
Broken blade. |
Impeller Salvage for 3208 Engines
Bore Salvage
The purchase of the special tool that this procedure needs is practical only if approximately twenty impellers can be salvaged.
Illustration 80 | g06280597 |
Cogsdill K5-154 Knurling Tool. |
The salvage procedure is as follows:
- Turn the adjustment screw of the Cogsdill K5-154 Knurling Tool until the distance across the roll is
16.41 mm (0.64606 inch) .Show/hide tableIllustration 81 g06280599 Knurl the bore at approximately 265 rpm 0.254 mm/revolution (265 rpm .010"/revolution). - Knurl the bore at approximately 265 rpm 0.254 mm/revolution (265 rpm .010"/revolution) on a lathe or drill press. Hand feed can be used. Use cutting oil or coolant during the procedure.
- After the knurling procedure, use a plug gauge to check that the bore dimension is correct.
Show/hide table
Illustration 82 g06280602 - Before assembly, clean the bore and mating shaft with 6V-1541 Quick Cure Primer and put 9S-3265 Retaining Compound on both parts.
Blade Salvage
To salvage the blade, grind to remove the tips on the inside of the blades. Remove any burrs from blade edges.
Illustration 83 | g06280604 |
Illustration 84 | g06280605 |
Remove the burrs from blade edges when grinding blade tips. |
Illustration 85 | g06280606 |
Impeller Visual Inspection
Illustration 86 | g06281554 |
(1) Impeller Blade
(2) Seal Face |
Illustration 87 | g03449876 |
Excessive damage to impeller bore. Do not reuse. |
Examine the blades of the impeller for damage and wear. Around the fins inspect for excessive damage, pitting, erosion, wear, and cracked or broken fins. Examine the bore for excessive wear, galling, scaring. Do not reuse an impeller that has any visible damage or wear refer to Illustration 87. If upon inspection the impeller blades do not meet reusability specification, then replace the impeller.
- The outside tip of the impeller blades should not have any grooves, scratches, or erosion.
- Check the entire length of each impeller blade for erosion or cracks. Damage to the blades cannot be repaired and the impeller must be replaced.
- Inspect seal face for pitting, erosion, and scratches. If there is any damage to the seal face, the impeller must be replaced.
Impeller Bore Specification
The impeller bore must meet certain diameter and surface finish specifications if it is to be reused without machining. The impeller bore (B) must be within
Illustration 88 | g06281557 |
(A) Seal bore diameter
(B) Shaft bore diameter |
Water Pump Impeller Bore Specifications for 3500 Engine | |||
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Part Number | Seal Bore Diameter
(A) |
Shaft Bore Diameter
(B) |
Salvaged Bore Diameter
C |
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N/A | |
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N/A | |
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N/A | |
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N/A | |
N/A | |
N/A |
Impeller Salvage for 3500 Engines
An impeller with a tapered shaft can be salvaged and machined to have a straight shaft. The machining operation involves machining the bore, de-burring the bore, and balancing the impeller.
- Machine the impeller bore (C) to the specification listed in Table 24.
- Machine the chamfer on the top face of the impeller to 25° and
1.25 ± 0.25 mm (0.049 ± 0.010 inch) deep. - De-burr the sharp edges as needed after machining the bore.
- The surface finish of the impeller bore should be inspected. The finish should measure 0.8 microns to be acceptable.
- After machining the impeller bore, it must be balanced. Refer to the section "Impeller Balancing" within this document.
Illustration 89 | g06281558 |
Critical dimensions for machining the bore (A) Angle of chamfer: 25° (B) Depth of chamfer: (C) Diameter of bore |
If the impeller bore measures less than the minimum size listed in Column (B) of Table 24, then the impeller can still be salvaged by knurling the inner diameter of the bore. If the impeller has signs of being knurled before, then the impeller cannot be salvaged and must be replaced. Knurling the impeller bore will raise the metal and make the bore diameter smaller. The knurling process can be completed by following:
- Refer to Column (C) of Table 24 to find the minimum bore diameter. Not all impellers can be knurled, those that can be knurled will have a dimension in Column (C) of Table 24. Machine the inside diameter of the impeller bore oversize by the dimension listed in Column (C). If the impeller bore measures greater than the oversize dimension listed in Column (C) before machining, then the impeller cannot be salvaged.
Show/hide table
Illustration 90 g03464738 Example of Caterpillar Inc CNC knurling tooling. - Using appropriate knurling tooling, apply a cross hatch knurl such that the inner diameter of the impeller bore is . The exact angle of hatch is not as critical as it is to knurl the entire bore depth. Use a hatch angle between 30° and 60°, it is important to use a hatch at an angle less than 90°. Knurling the entire depth of the bore is important to ensure equal raising of material to provide adequate friction when installing the impeller onto the shaft.
Impeller Balancing
Illustration 91 | g03464458 |
One example of a balancing machine setup. |
If the impeller bore has been machined or knurled, then the impeller must then be rebalanced. The impeller can be balanced either statically or dynamically. The impeller must be balanced to within 0.35 grams-meter. Use a drill and drill bit to remove material as the impeller is balanced. If the impeller is out of balance, it can be balanced using the following criteria.
Illustration 92 | g06281560 |
Critical balancing dimensions (A) Radius to drill balancing holes. (B) Minimum spacing between balancing holes. (C) Balancing hole. |
Illustration 93 | g06281563 |
Critical balancing dimensions (A) Radius to drill balancing holes. (B) Minimum spacing between balancing holes. (C) Balancing hole. |
Illustration 94 | g06281563 |
Critical balancing dimensions (A) Radius to drill balancing holes. (C) Balancing hole. |
There are various styles of impellers, but they are all balanced in a similar fashion. When balancing the impeller, the relief holes must be centered on the radius and spacing listed in Table 25. Refer to Illustrations 92 ,93, and 94.
Water Pump Impeller Balancing Specifications for 3500 Engines | ||||
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Impeller Part Number | Balance Hole Radius | Max. Bit Size | Max. Bit Depth | Min. Spacing |
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Water Pump Modifications for 3500 Engines
This section highlights the major modifications to the water pump. The water pumps have been updated over time to provide a more robust pump. At the time of rebuild an older water pump can be updated to reflect the current production water pump. The following chart identifies the water pump groups that are direct replacements for the former water pump groups and which modifications are necessary.
(1) | Requires no modification. |
(2) | Requires seal retaining pin modification. |
(3) | Requires shaft upgrade. |
(4) | Requires seal group replacement. |
(5) | Requires thrust washer replacement. |
Ring Assembly Modification
To modify the water pump housing to accept the new ring assembly, a hole must be drilled in the housing. This new hole will accept the pin of the ring assembly. The pin keeps the ring assembly positioned with the opening in the ring toward the bottom of the installed water pump. This opening allows any fluid that leaks past the water pump seals to get to the water pump weep port.
Illustration 95 | g03355823 |
Typical ring and pin assembly |
The Ring Assembly is used on some water pumps. Some older style 8N-1005 Pump Housings did not originally have a ring assembly and spring pin. Those pump housings can be identified by the lack of a spring pin hole opposite of the weeping hole. Pump housings without the spring pin hole must be modified by drilling a
Illustration 96 | g06281533 |
Fixture Dimensions for 3500 Engines | |
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Callout | Dimension |
A | 5/16 - 18 |
B | Three Places |
C | |
D | |
E | |
F | |
G | |
H | |
I | Radius |
J | |
K | |
The following illustration shows the location of the new hole in the housing assembly if you choose not to use the fixture.
Illustration 97 | g06281535 |
The hole needs to be |
Illustration 98 | g06281539 |
(M) Drilling fixture positioned onto the water pump housing (P) Hole in housing that was drilled |
Tooling Required for 3500 Engines | ||
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Callout | Qty | Description |
N | 1 | 1A-LS-Lock Screw |
O | 1 | L-32-12 5/16 ID Liner Bushing |
Q | 1 | SF-20-22 .0985 ID Drill Bushing
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R | 2 | 5/16-18 x 1 SHCS |
S | 2 | HL-32-8 5/16 ID Liner Bushing |
Shaft Replacement
The tapered shaft is not a serviceable part. It must be replaced with a current straight shaft. Refer to the Parts Manual for the correct part numbers. The impeller that matches the tapered shaft can be modified to fit a straight shaft. Refer to the section "Impeller Salvage for 3500 Engines" found within this document.
Illustration 99 | g06281541 |
Seal angle for a |
Illustration 100 | g06281543 |
Seal angle for a |
Some water pump models have updated the angle near the oil seal and applied a radius. This new angle is to prevent damage to the oil seal during assembly. The 212-8179 Shaft has been replaced with the 430-9695 Shaft. Refer to Illustrations 99 and 100 in this document. If you have the 212-8179 Shaft, then it must be replaced with a 430-9695 Shaft at the time of rebuild.
Seal Group Replacement
The seal group must be replaced at every rebuild. The current 416-0603 Seal Group is a direct replacement for the 166-4375 Seal Group and the 124-5245 Seal Group found in former water pumps.
Disassembly
Refer to the appropriate Disassembly and Assembly manual for specific instructions.
Illustration 101 | g03465157 |
(1) Sleeve Bearing
(2) Thrust Washer |
Illustration 102 | g03465184 |
Example of a hydraulic sleeve bearing puller. |
Some pumps have a sleeve bearing (1) installed refer to Illustration 101. The updated thrust washer makes removal of the thrust washers impossible with the sleeve bearing still in the housing. During disassembly, the sleeve bearing must be removed first, then the thrust washers unbolted and then the shaft pressed out. The sleeve bearing (1) must be removed without damaging the pump housing.
Proper support of the water pump housing is critical for a successful disassembly. The use of a steel support plate in Illustration 103 is highly recommended. When pressing the shaft off the impeller and out of the housing the water pump housing must be fully supported to prevent flexing. If the housing flexes, then the housing can crack and destroy the housing. Refer to Illustrations 103 and 104 for an example of a supported water pump.
Illustration 103 | g06281545 |
Support plate used for removal of the shaft. (A) (B) (C) (D) |
Illustration 104 | g03444021 |
Water pump successful disassembly. |
Assembly
Refer to the appropriate Disassembly and Assembly Manual for a detailed procedure of the entire assembly process. This is a condensed version with the intent to highlight critical steps.
- Install plugs.
- Install the oil seal.
- Lubricate the shaft with clean water. Then insert the shaft and thrust washers. Tighten the thrust washer bolts.
- If a bearing sleeve was removed, install a new bearing sleeve.
- Flip the housing over. Apply P80 lubricant to the bottom half of the shaft. Using a press, install stationary portion of the water seal into the housing. Constant force is required when installing the seal to prevent damage to the seal face.
Do not use a hammer and punch to install the water seal into the housing.
- Using the 438-8155 Adapter, install the 416-0603 Seal over the water pump shaft by hand with a rotating motion. Take care not to scratch the face of the seal as it will cause a leak.
- Place impeller onto shaft. Press the impeller onto shaft with a hydraulic press until impeller and shaft are flush.
Thermal Spray Procedures for Water Pump on C27 & C32 Engine
Illustration 105 | g03145381 |
Illustration 106 | g03145382 |
C27 & C32 Water Pump | ||
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Dimension A | Dimension B | Dimension C |
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Dimension D | Dimension E | Dimension F |
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Illustration 107 | g03154117 |
C27 & C32 Water Pump | ||
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Dimension G | Dimension H | Dimension I |
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Dimension J | Dimension K | |
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N/A |
Part Description
Base Metal | Grey Iron Casting |
Hardness | 187-241 BHN |
Arc Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear, grooving, or corrosion |
Mating Part Contact Area & Material | Engine cover and o-ring |
Arc Spray Equipment Type | SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU |
Wire | TAFA 30T Wire Top Coat, TAFA 75B Bond Coat |
Finish Thickness | As required |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | Filtered shop air |
Rotation/Traverse Device | Lathe |
Rotation Speed | |
Surface Preparation Method | Undercut and Grit blast |
Equipment Required | Turn (Horizontal or Vertical) Lathe |
Recommended Cutting Tool | ISCAR DNMG 432TFIC507 |
Blast Media Recommendation | Pressure Type Only (Aluminum Oxide Grit) |
Arc Spray | Procedure | Check List | ||
Clean Part | Degrease in hot caustic solution | |||
Undercut | If desired | |||
Chamfer | If required - |
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Remove Oxide | Use emery cloth or glass bead blaster | |||
Clean Spray Area | Commercial degreaser | |||
Mask for Grit Blaster | 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 | Duct tape, metal shield, or rubber | |||
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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Rotation Speed of Part | |
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Traverse Rate of Gun | |
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Gun Fixturing Method | Machine mount or hand held | |||
Finishing Equipment | Milling machine | |||
Part/Cutter Rotation Roughing | |
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Part/Cutter Rotation Finishing | |
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Coolant | Oil base synthetic - 40:1 ratio | |||
Traverse Speed | |
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Depth of Rough Cut | |
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Depth of Finish Cut | |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear, grooving, or corrosion |
Mating Part Contact Area & Material | Engine cover and o-ring |
Metco Equipment Type | 6P-II by Oerlikon Metco |
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 Device | Lathe |
Rotation/Traverse Device | |
Surface Preparation Method | Undercut and Grit Blast |
Finishing Method | Machine |
Machining Equipment Type | Lathe or Horizontal Mill |
Recommended Cutter Grade | C-2, 883 Carboloy or equivalent |
Flame Spray Process (6P) | Procedure | Check List |
Clean Part | Degrease in hot caustic solution | |
Undercut | To "tru-up" surface | |
Chamfer | If required - |
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Remove Oxide | Use fiber flap brush or Clean/strip disc | |
Clean Spray Area | Metco clean solvent or equivalent | |
Mask for Blast | Duct Tape | |
Blast Equipment | Pressure type only | |
Grit Type and Size | 24 mesh Aluminum Oxide | |
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 Spray | Metco Antibond or Blue Layout Dye | |
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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Rotation Speed of Part | |
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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 | Lathe or Horizontal Mill | |
Part/Cutter Rotation | |
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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 cloth for desired finish |
Thermal Spray Procedures for Water Pump Housing Bore on 3208 Engines
Illustration 108 | g03046939 |
Part Number | Dimension A | Dimension B |
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Part Description
Base Metal | Cast Iron |
Hardness | N/A |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
Reason for Spraying | Wear |
Mating Part Contact Area & Material | Bearing - press fit |
Metco Equipment Type | 6P-II |
Metco Material | 452 or 453 |
Metco Sealer | 185 |
Finished Thickness | As required |
Finishing Allowance | |
Spray Angle | 81° to bore |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Rotation/Traverse Device | Lathe or turntable |
Rotation/Traverse Speed | |
Surface Preparation Method | Grit blast |
Finishing Method | Machine |
Machining Equipment Type | Lathe |
Recommended Cutter Grade | C-2 carbide |
Remarks |
Flame Spray Process (6P-II) | Procedure | Check List |
Clean Part | Wash in non-oil base solvent | |
Undercut | Not required | |
Chamfer | All edges - 45° x |
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Remove Oxide | Emery paper or glass beading | |
Mask for Blast | Metal mask |
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Blast Equipment | Pressure blast | |
Grit Type and Size | G-25 angular steel | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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Remove Blast Mask | Remove | |
Mask for Spray | Use METCO Anti-Bond - Install snap ring in groove | |
Spray Equipment Type | 6P-II | |
Nozzle | 6P7C-K "K" | |
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) | 470 | |
Rotation Speed of Part | |
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Traverse Rate of Gun | |
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Gun Fixturing Method | Hand held or machine mount | |
Bond Pass/Thickness | |
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Top Coat/Thickness | As required | |
Finishing Equipment | Lathe | |
Part/Cutter Rotation | |
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Traverse Speed | |
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Depth of Rough Cut | |
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Depth of Finish Cut | |
Note: Do not direct flame on area to be sprayed.
Thermal Spray Procedures for Water Pump Shaft on D348, D398, G398, and D399 Engines
Illustration 109 | g03050142 |
Part Number | Diameter A (Bearing) | Diameter B (Seal) |
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Part Description
Base Metal | Alloy Steel |
Hardness | RC 45 min |
Flame Spray Equipment and Procedure
Surface Texture | Diameter A: Diameter B: |
Reason for Spraying | Wear |
Mating Part Contact Area & Material | Seal and bushings |
Metco Equipment Type | 6PHII |
Metco Material | 447 or 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 46J or 46K |
Machining Equipment Type | N/A |
Recommended Cutter Grade | N/A |
Other Equipment Type | Belt 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 | |
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 tape and paint | |
Mask for Spray | With Anti-Bond | |
Spray Equipment Type | 6PII | |
Auxiliary Cooling | A J Siphon | |
Nozzle | 6P7C-K "K" Nozzle | |
Air Capacity/Pressure | 6P-3 Cool side out - |
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Extension | N/A | |
Air Jets/Pressure | N/A | |
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/Bond Pass | N/A | |
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 | |
Bond Pass/Thickness | N/A | |
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 D9H Water Pump Housing
Illustration 110 | g03080261 |
A | |
B | |
C | |
D | |
Part Description
Base Metal | Gray Iron |
Hardness | - |
Flame Spray Equipment and Procedure
Maximum Surface Finish | 140 Microinches |
Reason for Spraying | Erosion |
Mating Part Contact Area & Material | Impeller, Cover |
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 | AJ, If desired |
Rotation/Traverse Device | Lathe or Turntable |
Rotation/Traverse Speed | |
Surface Preparation Method | Hand grind erosion before grit blasting. Grinding removes contamination. Undercut (machine) wear surface area. |
Finishing Method | Machine |
Machine 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 | |
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Chamfer | 45° | |
Remove Oxide | Use fiber flap brush, Clean/strip disc | |
Mask for Blast | Use metal, rubber, or 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 | |
|
Mask for Spray | Antibond or sheet metal layout dye | |
Spray Equipment Type | 6P-II Thermo Spray System | |
Auxiliary Cooling | Metco AJ Siphon Air Jet | |
Nozzle | 6P-C7A-K "K" Nozzle | |
Air Capacity/Pressure | 6P-3/Pinch Air |
|
Oxygen Pressure | |
|
Oxygen Flow | |
|
Fuel Gas Pressure | |
|
Fuel Gas Flow | |
|
Carrier Gas Pressure | |
|
Carrier Gas Flow | |
|
Spray Rate/Build Up | |
|
Gun to Work Distance | |
|
Rotation Speed of Part (RPM) | 165 RPM | |
Rotation Speed of Part | |
|
Traverse Rate of Gun | |
|
Gun Fixturing Method | Hand Held | |
Top Coat/Thickness | |
|
Finishing Equipment | Lathe | |
Part/Cutter Rotation | |
|
Traverse Speed | |
|
Depth of Rough Cut | |
|
Depth of Finish Cut | |
Storage Procedures
Proper protection of the water pump from corrosion is important. Corrosion will start in as little as one hour after the water pump has been cleaned.
When the water pump will not be inspected for one hour or less the water pump should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The water pump should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 111.
When the water pump will not be inspected in two days or more the water pump should be coated with a rust or corrosion inhibitor or coated with clean engine oil and 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 water pump. See Illustration 112.
Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
Illustration 111 | g06278538 |
Example of protection for a component that is stored for a shorter term |
Illustration 112 | g06278539 |
Example of protection for a component that is stored for a longer period |