Outboard Bearing Removal Procedure for Integrated Throttle Body (ITB) on Certain 3500 Engines {1269} Caterpillar

Engine

G3508 (S/N: 9TG1-UP; WPM1-UP; WPN1-UP; DLR1-UP)

G3508B (S/N: JB31-UP; N8C1-UP; RBK1-UP)

G3508J (S/N: N8W1-UP)

G3512 (S/N: 7NJ1-UP; E2N1-UP; E2P1-UP; WPP1-UP; WPR1-UP; E2S1-UP; GNS1-UP; E2T1-UP; E2X1-UP)

G3512B (S/N: JHH1-UP; N2S1-UP; JBW1-UP)

G3512E (S/N: NWC1-UP; GFM1-UP; SSR1-UP; NGS1-UP; SST1-UP)

G3516 (S/N: AL71-UP; ZBA1-UP; L6E1-UP; L6G1-UP; 4EK1-UP; WPS1-UP; CSZ1-UP)

G3516B (S/N: CW51-UP; N6E1-UP; JEF1-UP)

G3516C (S/N: GG31-UP; NG61-UP; GSB1-UP; TJB1-UP; GZC1-UP; TJC1-UP; F6D1-UP; NWD1-UP; F6E1-UP; G7E1-UP; NWE1-UP; F6F1-UP; NWF1-UP; F6M1-UP; N6R1-UP; GZZ1-UP)

G3516E (S/N: F6G1-UP; NWG1-UP; GAS1-UP; SLY1-UP)

G3516J (S/N: N6W1-UP)

G3520 (S/N: HET1-UP)

G3520B (S/N: GLF1-UP; GET1-UP)

G3520C (S/N: GZA1-UP; HEA1-UP; GZB1-UP; HEB1-UP; MAD1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; RLP1-UP; LGS1-UP; HAT1-UP; CWW1-UP; CWY1-UP)

G3520E (S/N: GZE1-UP; GZG1-UP; GZH1-UP; HAL1-UP; SXY1-UP)

G3520J (S/N: N221-UP; N241-UP)

Petroleum Engine

G3520B PETROLEUM (S/N: TPC1-UP)

Power Module

PMG3516 (S/N: GJK1-UP; JKK1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction describes the rework procedure for replacing the outboard bearing for the Integrated Throttle Body (ITB).

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Required Parts

Table 1 contains the parts for the 555-1602 Bearing Kit. The bearing kit is serviceable as a whole and not by individual parts.

Required Tools

Loctite^® 243 Blue Threadlocker

Loctite^® Silver Grade Anti-Seize Stick

Krytox^™Lubricants

Kano Laboratories^® Kroil Penetrating Oil

Table 3 contains the parts for the 554-5061 Tool As-Removal. The tool removal assembly is serviceable as a whole and not by individual parts.

Verification Procedure

Before replacing the outboard bearing, it is important to be sure that the bearing needs replaced. To determine the health of the bearing, follow the steps below.

1. Power-down the ITB.

2. Move the valve by repositioning the pointer by hand.

   Note: A good bearing will allow the valve to move smoothly and easily.

3. If the valve is difficult to move, or the valve does not move at all, then the bearing has likely failed.

Overview

Illustration 1	g06322742
(A) Pointer (B) Pointer Screw (C) Spring Seat (D) Spring (E) Seal Assembly (F) Cap O-ring (G) Cap (H) Bearing (J) Cap Screw

Illustration 1 shows an example of the parts that will be replaced.

Removal Procedure

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Illustration 2	g06323349
Example of pointer location (A) Pointer (B) Pointer Screw (K) ITB Housing

1. Close the throttle valve by hand and mark the location of pointer (A) on ITB housing (K).

2. Unscrew pointer screw (B).

3. Remove pointer (A).
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   Illustration 3	g06324144
   (G) Cap (J) Cap Screws (T1) Allen Key 4 mm (5/32 inch)

4. Using allen key (T1), unscrew cap screws (J) together evenly from cap (G) to prevent damage to the ITB housing.
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   Illustration 4	g06323354
   (C) Spring Seat (D) Spring (E) Seal Assembly (F) Cap O-ring (G) Cap

5. Remove cap (G), seal assembly (E), and cap o-ring (F).

6. Remove spring seat (C), and spring (D).
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   Illustration 5	g06323357
   Example of shaft and sealing surfaces

7. Inspect the shaft and housing sealing surfaces.
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   Illustration 6	g06323359
   (L) Bearing Seal (T2) Hooked Pick

8. Remove bearing seal (L) from the old bearing with a small screwdriver or hooked pick (T2).
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   Illustration 7	g06323381
   Example of bearing without seal (M) Bearing (T3) Kano Laboratories® Kroil Penetrating Oil

9. Soak bearing (M) and the surrounding area with Kano Laboratories^® Kroil Penetrating Oil (T3) or equivalent to help remove excess particles and help loosen the bearing from the shaft.

   Note: Let the solution sit for a minimum of 5 minutes.

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   Illustration 8	g06323383
   (T4) 554-5061 Tool As-Removal

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   Illustration 9	g06322934
   Exploded view of 554-5061 Tool As-Removal (T5) Collet (T6) Collet Sleeve (T7) Spring Pin (T8) Collet Handle (T9) Washer (T10) Jam Ring

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   Illustration 10	g06322950
   (M) Bearing Inner Race Lip (M) Bearing Inner Race Groove (T5) Collet Lip

10. Place the opening of the tool over bearing inner race lip (M). Collet lip (T2) should be centered over bearing inner race groove (M).
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    Illustration 11	g06323387
    (T6) Collet Sleeve (T8) Collet Handle

11. While using one hand to hold collet handle (T8) securely, use the other hand to tighten collet sleeve (T6). Turn the collet sleeve clockwise until resistance is felt. Once resistance is felt, stop tightening the collet sleeve. The tool should be securely engaged to the bearing.

    Note: The collet grips the bearing by hooking into the bearing inner race lip. This tool does not work by resistance/friction means. To prevent damage to the bearing remover tool, specifically the collet, do not over-tighten the sleeve.

12. Slide washer (T9) over the tool until the washer sits against the valve body.

13. Screw jam ring (T10) onto collet sleeve (T6) until the jam ring contacts the washer.
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    Illustration 12	g06323389
    (T6) Collet Sleeve (T10) Jam Ring

14. Hold collet sleeve (T6) and tighten jam ring (T10) by hand approximately 5 turns. At this point the old bearing should be free enough from the shaft to be removed by hand.
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    Illustration 13	g06323391
    (M) Bearing (T5) Collet (T6) Collet Sleeve

15. Remove the 554-5061 Tool As-Removal with bearing (M) from the ITB housing. Then, remove the old bearing from 554-5061 by loosening collet (T5) from collet sleeve (T6).

16. Ensure that all the bearing bore surfaces and parts are clean before proceeding.

Installation Procedure

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Illustration 14	g06323394
Example of ITB housing with the bearing removed

1. Wipe down the inside bore with a clean, dry cloth.
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   Illustration 15	g06323398
   Example of lubricated ITB bearing bore (T11) Loctite ® Silver Grade Anti-Seize Stick

2. Apply a light coating of Loctite ^® Silver Grade Anti-Seize Stick (T11) into the bearing bore.
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   Illustration 16	g06323342
   Example of new bearing in ITB housing

3. Install the new bearing in the housing.

   Note: The bearing should slide in place by hand. Do not use impact devices to install the bearing.

   Note: Make sure that the bearing is fully seated on the valve shaft.

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   Illustration 17	g06323405
   (3) ITB Shaft Journal (4) Cap O-ring (5) Seal Assembly

4. Apply a light coating of Krytox^™RFE PFPE Lubricant to shaft journal (3), cap O-ring (4), and seal assembly (5).
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   Illustration 18	g06323407
   (6) Spring Seat (7) Spring

5. Place spring (7) in the housing against the bearing.

6. Place spring seat (6) in the housing against the spring.
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   Illustration 19	g06323410
   Example of cap screws with Loctite ® 243 Blue Threadlocker applied (8) Cap Screws

7. Applying one drop of Loctite ^® 243 Blue Threadlocker on the threads of the two cap screws (8).
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   Illustration 20	g06323413
   (8) Cap Screws (9) Cap Assembly

8. Place the new cap assembly over the spring and washer and compress the assembly into the housing.

   1. Thread the new screws into the cap/ housing, alternating between screws to walk the cap down into the housing.

   2. Torque to 3.8 ± -.2 N·m (34 ± -2 lb in).
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   Illustration 21	g06323416
   (10) Pointer Screw (11) Pointer (T12) Loctite ® 243 Blue Threadlocker

9. Place pointer (11) on pointer screw (10) and apply one drop of Loctite ^® 243 Blue Threadlocker (T12) on the screw threads.
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   Illustration 22	g06323417
   (9) Cap Assembly (10) Pointer Screw (11) Pointer

10. Close the throttle valve by hand.

    1. Place pointer (11) on cap assembly (9), and align the pointer with the mark made on the ITB housing.

    2. Tighten the pointer screw to 3.5 ± 4.3 N·m (31 ± 38 lb in).
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    Illustration 23	g06323418
    Example of reassembled Integrated Throttle Body

11. After reassembly, to verify that no leakages are present, pressurize the system. Then, using a soap/water solution check for leaks around the cap/housing and cap/shaft interfaces.

    1. Pressurize the system with XX psi.

    2. Use a soap/water solution to check for leaks around all the ITB components.