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Desarmado y Armado
3612 and 3616 Engines
Número de medio -SENR3594-12 Fecha de publicación -01/08/2008                        Fecha de actualización -05/08/2008

   
i02586823

Idler Gears (Rear) - Install

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
6V-6080 Torque Multiplier Gp 1
5P-1748 Socket 1
A
4C-9451 Rear Idler Gear Wrench 1
4C-9452 Rear Idler Gear Wrench 1

9U-5932 (1) Torque Wrench Extension 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Illustration 1 g00636750
Earlier

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Illustration 2 g00610687
Later

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Illustration 3 g01303614
Earlier

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Illustration 4 g00610685
Later

Note: The rear housing was removed for illustrative purposes only.

1. If the bearing was removed from gear (26) , install the bearing in the gear. The bearing must
be 3.0 ± 0.5 mm (0.12 ± 0.02 inch) below the surface of the side of the gear that has the
smaller shoulder.

2. Place gear (17) in position on other gear (26) . Install the bolts.

3. Attach a suitable lifting device to gear (17) . The weight of gear (17) and other gear (26) is
approximately 55 kg (121 lb).

4. Place the following components in position on shaft (24) : gear (17) , other gear (26) and
retainer (21) . Install bolts (18) . Do not tighten the bolts at this time.

5. Attach a suitable lifting device to gear (17) . The weight of the gear assembly is approximately
85 kg (187 lb). Place gear (17) and shaft (24) in position in the rear housing through the
camshaft drive gear opening.

6. Attach a suitable lifting device to gear (17) through the opening for the accessory drive in the
rear housing. Disconnect the suitable lifting device from gear (17) through the camshaft drive
gear opening.

7. Align the teeth on gear (17) with the teeth on the crankshaft gear. Place shaft (24) in position

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on the cylinder block. Install bolts (25) . Refer to Specifications, "Gear Group (Rear)" for the
correct torque.

8. Tighten bolts (18) .

9. If the bearings were removed from gears (22) , install the bearings in the gears. The bearings
must be 3.0 ± 0.5 mm (0.12 ± 0.02 inch) below the flat surface of the gear. The inside diameter
of the bearings should be 150.002 ± 0.020 mm (5.9056 ± 0.0008 inch) after installation.

10. Place gear (22) and retainer (23) in position on shaft (19) . Install the bolts that hold these
components in place.

11. Attach a suitable lifting device to gear (22) . The weight of the shaft and gear (22) is
approximately 41 kg (90 lb). Place the shaft and gear (22) in position on the cylinder block
through the camshaft drive gear opening in the rear housing. Install bolts (20) . Refer to
Specifications, "Gear Group (Rear)" for the correct torque.

12. Repeat Step 10 and Step 11 for the other idler gear.

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Illustration 5 g00610680

13. Attach a suitable lifting device to drive shaft (1) . The weight of drive shaft (1) is
approximately 40 kg (88 lb). Place spacer (16) in position on the end of drive shaft (1) . This is
done on earlier engines only.

14. Install drive shaft (1) and spacer (16) . Align the dowel in drive shaft (1) with the dowel hole
in camshaft segment (3) . Install bolts (2) . Tighten all of bolts (2) by hand.

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Illustration 6 g00610676

15. Place plate (15) in position and install bolts (14) .

16. Place plate (12) in position on drive shaft (1) and install bolts (13) .

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Illustration 7 g00610662

17. Be sure that camshaft timing pins (6) are installed in both camshafts.

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Illustration 8 g01295208

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Illustration 9 g00636485

Note: The later engine has an adapter for the governor drive that is mounted on the camshaft
drive gear.

18. Place plate (11) in position on camshaft drive gear (7) and install bolts (8) .

19. Apply Tooling (C) to bolt (9) .

20. Attach a suitable lifting device to camshaft drive gear (7) . The weight of camshaft drive gear

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is approximately 35 kg (77 lb). Place the camshaft drive gear in position on the camshaft.
Install washer (10) and bolt (9) . Tighten bolt (9) by hand.

21. Remove the crankshaft timing pin from the timing location.

22. Turn the flywheel backward about 20 degrees.

NOTICE
If the crankshaft is turned more than 20 degrees, interference between
the pistons and the valves may occur.

23. Be sure that bolts (9) are hand tightened. Turn the flywheel in the direction of the normal
engine rotation until the crankshaft timing pin can be installed in the crankshaft. This
procedure holds the backlash in the timing gears in the direction of the normal engine rotation.

24. If the location of the crankshaft timing pin is missed, do not turn the flywheel in the opposite
direction in order to install the timing pin. If the crankshaft timing pin is missed, repeat Step
22 through Step 23.

25. Remove the camshaft timing pins. Remove the crankshaft timing pin.

26. Use Tooling (A) in order to tighten bolts (9) to a torque of 2000 ± 275 N·m (1480 ± 200 lb ft).

27. Strike plate (11) with a punch and a hammer. The punch must be made of brass or bronze.
This will seat the gear on the tapered drive shaft. Repeat Step 26. Repeat this procedure until
the torque does not change.

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Illustration 10 g01295531

28. Use Tooling (B) in order to tighten as many bolts (2) as possible to a torque of 135 ± 15 N·m
(100 ± 11 lb ft) on earlier models. On later models, bolts (2) should be tightened to a torque of
270 ± 40 N·m (200 ± 30 lb ft).

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29. Remove the timing pin from the crankshaft.

30. Rotate the engine and use Tooling (B) in order to tighten remaining bolts (2) .

31. Verify the correct camshaft timing. Refer to Testing And Adjusting, "Camshaft Timing".

32. Remove the camshaft and the crankshaft timing pins. Return these pins to the storage
locations.

33. Install the rear camshaft inspection covers on each side of the engine.

34. Install the cover over the location of the crankshaft timing pin.

35. Install the camshaft drive gear cover on the left side of the rear housing.

End By:

a. Install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Install".
b. Install the governor drive. Refer to Disassembly and Assembly, "Governor Drive - Install".

Copyright 1993 - 2010 Caterpillar Inc.   Sat Feb 13 18:39:35 EST 2010
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