Guideline For Reusable Parts And Salvage Operations

Procedure to Inspect and Salvage the Gear on 1W-5009 (D9N) and 6I-3746 (988F)
Crankshaft Assemblies Used in 3408 Engines

Media Number -SEBF8269-01 Publication Date -01/09/2000 Date Updated -20/12/2001

Procedure to Inspect and Salvage the Gear on 1W-5009

(D9N) and 6I-3746 (988F) Crankshaft Assemblies Used
in 3408 Engines
SMCS - 1204

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SEBF8269-01
September 2000
SMCS Code(s): 1204

GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE
OPERATIONS
Procedure to Inspect and Salvage the Gear on 1W-5009 (D9N) and 6I-3746 (988F) Crankshaft
Assemblies
Used in 3408 Engines

Summary of Revisions

Page Description

All Revised Format.

Introduction
This Guideline enables dealers and their customers to benefit from cost reductions
made possible through an established parts reusability and salvage program. Every
effort has been made to provide the most current and relevant information known to
Caterpillar Inc. Since the Company makes ongoing changes and improvements to its
products, this Guideline must be used with the latest technical information available
from Caterpillar to ensure such changes and improvements are incorporated where
applicable.

For questions or additional information concerning this Guideline, contact Caterpillar

Service Support Division, Dealer Support (309) 675-5156.

Summary
The 2W-3878 Gear on the crankshafts of some 3408 Engines may be misaligned or
incorrectly positioned. This Guideline provides the dimensions and procedures to check
the gear's alignment and location.

When used in the same application, crankshaft gears that meet the "Use again"
specifications in this Guideline can be expected to give normal performance until the
next overhaul. Never use a crankshaft assembly that this Guideline shows cannot be
used again.

References

Reference Material

Form No. Title

SENR3450 Service Manual (D9N)

SEBP1642-05 Parts Manual (D9N)

SEBP2236

SENR5720 Service Manual (988F)

SEBP2049 Parts Manual (988F) Serial No. 8YG1-UP

Tooling and Equipment

Tooling and Equipment

Part No. Description

--- Gear Installation Tool1

--- Dial Indicator and Magnetic Base or Depth

Micrometer

1P-2321 Puller Group

1
Refer to "Fabricated Tooling" for specifications to manufacture this tool.

Fabricated Tooling
The gear installation tool consists of a fabricated plate and ring which are
bolted together into an assembly. Illustration 1 shows the assembled
installation tool. Illustrations 2 and 3 show the dimensions to manufacture
the plate and ring.

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Illustration 1

Gear installation tool.

(1) Plate.

(2) Ring.

(3) 0S-1616 Bolt, 1/4-20 x 1.

(4) 5P-0537 Washer.

(5) 1A-4273 Bolt, 5/8-18 x 1 1/4.

(6) 5P-8247 Washer. (A) Ground surface.

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Illustration 2

Specifications for manufacturing plate (1) made from SAE 1020 steel. Refer to Chart A for item identification and
dimensions.

Chart A.
Specifications for Plate (1)

Item Description

A Grind this side flat, after holes have been drilled. A

flatness of 0.03 (.001) must be maintained.

B 12.7 ± 1.5 (.50 ± .06)

C 254 ± 3 (10.0 ± .12)

D 76 ± 3 (3.0 ± .12)

E 127 ± 3 (5.0 ± .12)

F 90.0 (3.55)

G 66.0 (2.60)
 H 19.0 (.75)

I 8.0 (.31) diameter holes (4 places)

J 54.00 (2.125) diameter hole

K 19.0 (.75) diameter holes (2 places)

Note: All dimensions are mm (in)

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Illustration 3

Specifications for manufacturing ring (2) made from SAE 1020 steel.
Refer to Chart B for item identification and dimensions.

Chart B.

Specifications for Ring (2)

Item Description

A 27.76 ± 0.03 (1.093 ± .001)

B Grind both sides flat after holes have been drilled.

A flatness of 0.03 (.001) must be maintained.
 C 203.00 ± 0.50 (8.000 ± .020)

D .00 ± 0.5 (6.500 ± .020)

E 90.0 (3.55)

F 19.0 (.75)

G 1/4-20 2B thread
12.7 (.50) deep (4 holes)

Note: All dimensions are mm (in).

Inspection
Two variables will be measured with this inspection procedure:

1. The runout of the front crankshaft gear.

2. The depth of the crankshaft gear in relation to the front face of the crankshaft.

Care must be used to ensure the stability and accuracy of the tools being used
when performing the inspection procedure. This inspection procedure requires a
magnetic base with the dial indicator or a depth micrometer to take the required
measurements. Whichever tool is used, the measuring device must be positioned
correctly to obtain accurate and consistent measurements.

Procedure
1. Remove the belts, crankshaft pulley, damper, and front crankshaft seal.

Note: Refer to the appropriate service manual for the correct tools and procedure for the
proper removal of the crankshaft seal.

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 Illustration 4

Check dimension (A) using dial indicator or depth micrometer. (A) 26.41 mm (1.040 in) minimum to 28.95 mm (1.140 in)
maximum.

2.
3. Measure the location of the gear in relation to the crankshaft's front face. Use a
depth micrometer or a magnetic base and dial indicator, check distance (A) from
the front crankshaft face (1, where the damper contacts the crankshaft) to the
face of crankshaft gear (2) as shown in Illustration 4.

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4. Illustration 5
5. Take measurements for dimension (A, Illustration 4) at twelve locations as shown in the illustration.

6. Measure and calculate the runout of the gear.

a. Make twelve measurements equally spaced across from every hole of the
crankshaft face.
b. Record the measurements in Chart C.

Chart C.

Runout Measurements for Dimensions (A)

Location Measurement Obtained

(record the measurements in the blanks)
 1

10

11

12

c. Calculate the runout of the gear by subtracting the minimum measured distance
from the maximum measured distance.

1. If the run out measurement is 0.25 mm (.010 in) or less, and the gear is within
the specified dimension (A), the gear alignment is acceptable. Install a new 2W-
1733 Seal and a 4W-8089 Damper.
2. If the runout measurement is greater than 0.25 mm (.010 in), the face of the gear
is not within the specified dimension (A, Illustration 4), or the gear was
repositioned previously, replace the gear train and damper assembly using the
"Salvage Procedure" in this Guideline.

Salvage Procedures
Before starting the salvage procedure, fabricate the gear installation tool as
shown in the "Fabricated Tooling" section.

Gear Removal
This procedure can be completed without removing the engine from the machine.
1. The front gear train must be replaced along with the front crankshaft damper.
2. Pin time the fuel pump and flywheel.
3. Support the front of the engine, with overhead support, before proceeding with
disassembly of the front gear train.
4. Drain the sump oil.
5. Remove the oil pan, front main bearing cap, and oil pump.
6. Remove the water pump and lines to allow removal of the front housing.
7. Remove the automatic timing advance cover and front housing.
8. Move the camshaft forward.

a. Remove the 3T-5447 Hydraulic Pump and Drive from the flywheel housing.
b. Remove the rear 2W-8038 Camshaft Gear.

1. Remove valve covers.

2. Using the appropriate tools, pull the push rods and valve lifters out of the way
[lifters need to be pulled up approximately 25 mm (1.0 in)] to allow movement of
camshaft.

NOTICE

Using excessive heat to remove the gear

may cause damage to the crankshaft. Do
not heat the gear over 204øC (400øF).
3.
4. Remove the crankshaft gear using the 1P-2321 Puller Group. Heat the gear with
a torch to ease its removal.
5. After removing the crankshaft gear, check the front crankshaft gear journal
dimension at four equally spaced locations (12 O'clock, 1:30, 3:00, and 4:30).
The measurement should be 158.75 +/- 0.03 mm (6.250 +/- .001 in). If the journal
is undersized, the crankshaft may need to be replaced, which requires removal of
the engine from the machine. Before removing the engine, please contact the
3400 Service Engineer, at (309) 578-4436 or (309) 578-8629.

Note: The 2W-3878 Crankshaft Gear should have a bore with an inside diameter
of 158.620 +/- 0.03 mm (6.245 +/-> .001 in). The interference fit between the
gear and the crankshaft should be a minimum of 0.075 mm (.0030 in).

6. Remove the camshaft thrust plate bolts to allow the camshaft to slide forward.
Slide the camshaft forward no more than 38.0 mm (1.50 in).
7. Remove the 6I-3749 Idler and Weight Gear Assembly by removing the four 2B-
2695 Bolts. Slide the assembly forward the same distance as the camshaft was
moved.
8. Remove the five bolts holding the 7N-2484 Idler Drive Shaft to the block (refer to
Parts Book SEBP2049, 6I-3745 Front Gear Group).
9. After the five bolts are removed from the block, the drive shaft will slide forward
out of the block.
10. The 6I-3749 Idler and Weight Gear Assembly and drive shaft will now slide
sideways away from the camshaft gear.
 Note: The parts book does not show a 6I-3749 Idler and Weight Gear Assembly.
This is the parts service gear assembly for 6I-3750 Gear Assembly and 4N-0343
Sleeve Bearing.

11. Remove the 2W-8375 Gear (Oil Pump) and the 100-8178 Gear (Oil Pump Idler).
12. Install a new 2W-3878 Gear onto the crankshaft.

Gear Installation
1. Heat the crankshaft gear to 204 C (400 F), for one hour before installation.

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To avoid burns, use adequate gloves to

handle the heated gear.

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3. Illustration 6
4. Install the gear onto shoulder of crankshaft.

5. (A) 3.0 mm (.12 in).

6. (1) Gear slot and alignment dowel pin.

7. (2) Block.

8. (3) Crankshaft.

9. Install the gear onto the crankshaft journal aligning the slot in the gear with the
dowel (1) in the crankshaft. Install the gear 3.0 mm (.12 in) from the shoulder of
the crankshaft as shown in Illustration 6.

Note: The elapsed time from removal of gear from the heating unit to installation
onto the crankshaft should be no more than one minute.
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Illustration 7

Push the gear, using the installation tool, onto the shaft to its final location.

(2) Block.

(3) Crankshaft.

(4) 1A-4273 Bolt and 5P-8247 Washer.

10. Use the fabricated gear installation tool to finish pushing the gear onto the
crankshaft to the proper depth as shown in Illustration 7. This must be done
before the gear shrinks and locks
11. Once the plate portion of the tool is against the face of the crankshaft, install and
tighten the two bolts (4). This will hold the tool in place until the gear cools. The
gear must be against and flush with the ring of the installation tool.

Note: Some force may be required to align the gear if it has cocked during
installation.
 12. After the gear has cooled, check to make sure the runout of the gear and the
depth on the crankshaft is correct. The gear runout should not exceed 0.25 mm
(.010 in).
13. Install a new 6I-3749 Gear Assembly (Idler Gear and Bearing Assembly), 100-
8178 Gear (Oil Pump Idler), and 2W-3875 Gear (Oil Pump).
14. Slide the camshaft into its correct position and install the valve lifters, push rods,
and valve covers.
15. Install the rear camshaft gear, 3T-5447 Hydraulic Pump and Drive, automatic
timing advance, timing gear cover, new 2W-1733 Seal, crankshaft pulley, 4W-
8089 Damper, belts, front engine support, oil pump, front main bearing cap, and
oil pan. Replace the engine oil.

Notes

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