Reuse and Salvage of Water Pumps

1/30/24, 3:42 PM SIS 2.
Reuse and Salvage of Water Pumps {1361} (SEBF8418-32)
SMCS - 1361 i09950578

Caterpillar Products
All Cat Engines
Revision History:
Table 1
PIP
-
202 1046
Revision Summary of Changes in SEBF8418
32 Added 579-5381 to, and updated Tables 34 and 35.
Added serial numbers for NPI
31
30
4
12: 01/3 666 4
Added Illustrations 6, 7, 817,18,19, 47, and 48.
Added Tables 5, 6, 7, 15, and 16.
Added serial numbers for NPI /
4
Added 355-7389 to Tables 34 and 35.
SEB 2:13+ 0
Removed the Crack Detection Methods Section and added a reference to SEBF8148.
29
27-28 Added serial numbers for NPI
© 2 F841 03:00
26
Added Image43 and Table11.
0 2 8
Revision 20 of this document is the result of the combination of SEBF2126, SEBF2128, SEBF2157, SEBF8058, SEBF8110, SEBF8276, SEBF8740,
SEBF9042, and SEBF9267.
Cat 4 C
Introduction
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
llar
therein without permission may be violation of intellectual property law.
fide r:
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
l Ye .
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
llow
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).
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
https://sis2.cat.com/#/print-preview/service/84939b58-e8f6-488d-b050-32efccf27286 1/67
1/30/24, 3:42 PM SIS 2.0
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.
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 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.
References
1/30/24, 3:42 PM SIS 2.0
Note: Refer to the appropriate Remove and Install (R&I), Disassembly and Assembly (D&A), and Operation and Maintenance Manual (OMM) for the part
or machine of focus before initiating this inspection or procedure.
Table 2
References
Media Number Publication Type & Title

"Why Reuse and Salvage Parts"
Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Cat Inspect https://catinspectweb.cat.com/
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
SEBF8148 Reuse and Salvage Guidelines , "General Salvage and Reconditioning Techniques"
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"
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 Designation
— (1) Personal Protective Equipment (PPE) Personal Protection

Component
— (2) Tool (Cribbing) Repositioning
and Movement
Component
— Suitable Lifting Device Repositioning
and Movement
1U-7262 Telescoping Magnet General Tooling
Caliper Profile
4S-9405
304.8 mm (12.00 inch) Measurement
Scale
152.0 mm (6.00 inch) Steel Rule with Clip Measurement
9U-7289
Front side has dual scale metric mm and (32nd ± 64th inch) Checks
Back side has Metric/mm equivalent
Tool Measurement
5P-3920
304.8 mm (12.00 inch) Steel Rule Checks
Tool (Ruler)
Measurement
386-3364 1,000.0 mm (39.37 inch)
Checks
Straight Edge
Flatness/
— Straight Edge Straightness
Checks
1/30/24, 3:42 PM SIS 2.0
Thickness
Feeler Gauge
8H-8581 Measurement
0.038 - 0.635 mm (0.0015 - 0.0250 inch)
Checks
Tools (Micrometer) Internal
385-9422 Internal Measurement
2 - 24 inch Checks
Instrument Group
Micrometer, Inside
473-8688 2.00 - 12.00 inch Internal
or Measurement
473-8689 Instrument Group Checks
Micrometer, Inside
50 - 300 mm
Instrument Group
Micrometer, Inside
474-3709 8.00 - 32.00 inch Internal
or Measurement
474-3710 Instrument Group Checks
Micrometer, Inside
200 - 800 mm
Micrometers External
431-4150 External Measurement
0 - 25 mm (0 - 1 inch) Checks
Instrument Group External
473-8690 Micrometer, Outside Measurement
0.00 - 4.00 inch Checks
473-8691 Micrometer, Outside Measurement
2.00 - 6.00 inch Checks
473-8692 Micrometer, Outside - Digital Measurement
152.4 - 304.8 mm (6.00 - 12.00 inch) Checks
Threaded Hole
— (2) Plastic Plug Assortment
Protection
Surface
1U-5516 Disc (Coarse) Preparation
/ De-burring
Surface
1U-5518 Threaded Shaft Preparation
/ De-burring
Surface
1U-5519 Holder (Disc Pad) Preparation
/ De-burring
Wheel Surface
4C-8514 2 x 1 inch Preparation
(60 Grit) / De-burring
Grinding Wheel (F-Grade) Surface
4C-8515 2 x 1 inch Preparation
(120 Grit) / De-burring
Abrasive Disc
Surface
Disc size and Hole Diameter
1U-6832 Preparation
114.3 x 22.23 mm (4.50 x 0.875 inch)
/ De-burring
Aluminum Oxide 100 Grit
Grinding Wheel
Surface
Diameter and Length
1U-6825 Preparation
22.23 x 50.8 mm (0.875 x 2.00 inch)
/ De-burring
Aluminum Oxide A60 Grit
Wheel Surface
4C-8519 76.2 x 25.4 mm (3.00 x 1.00 inch) Preparation
180 Grit / De-burring
Surface
4C-8521 Wheel Adapter Preparation
/ De-burring
Surface
Die Grinder
222-3076 Preparation
(Right Angle)
/ De-burring
Brush Surface
254-5319 76.2 x 50.8 mm Preparation
(3.00 x 2.00 inch) / De-burring
1/30/24, 3:42 PM SIS 2.0
1P-0510 Driver Group Installation/Removal

1U-6395
O-ring Assembly Compound General Use
369-9450
5F-7465 Puller Part Removal
6V-1541 Quick Cure Primer General Cleaning
6V-2010 Polishing Stone Burr Removal
7N-8268 Installation Tool Installation
Minor
6V-6147
Polishing Wheel Scratch
8T-7748
Removal
9N-0137 Gasket Seal
9S-3265 Retaining Compound General Use
438-8155 Adapter Installation Tooling
FT-1704 Impeller Installer Impeller Installation
FT-1732 Drill Fixture Part Stabilization
KBN-625 Cogsdill Knurling Tool Knurling
K5-154 Cogsdill Knurling Tool Knurling
1U-9918 Brush General Cleaning
1U-5512 Abrasive Material
General Cleaning
467-0158 Roll
8T-7765 Surface Reconditioning Pad (180 Grit) General Cleaning
162-5791 Towel General Cleaning
Tool Group
8T-5096 Run-Out Checks
Dial Indicator
9S-8903 Indicator Contact Point Run-Out Checks
Welding
Preparation
222-3074 Wheel Grinder Group
Weld Removal/
Crack Excavation
Surface Texture
9A-1593 Comparison Gauge (Surface Texture)
Tester
Indicator Surface Texture
448-3698
(Profilometer) Tester
Paint
458-9587 (3) Touch Up
Yellow
Paint
479-5400 (4) Touch Up
Yellow
(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.
(2) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
(3) Available in North and South America (except Canada).
(4) Available in Canada, APD, and EAME.
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.
1/30/24, 3:42 PM SIS 2.0
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.
Note: Clean exterior of the water pump prior to disassembly to minimize cross-contamination.
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.
Bore Diameters
Typical example of measuring bore Inside Dimension (ID).
(A) Indicates the diameter of the bore
(B) Indicates the overall thickness of the material
Note: Measurements taken on the edge of a bore may not give an accurate measurement.
Take measurements at locations (A1), (A2), and (A3).
Then take measurements at locations (A4), (A5), and (A6).
To ensure adequate life of the components, this document contains precise tolerances for measurements taken on various features. Ensure that several
sample measurements are taken at different locations on the same feature. Measure diameters of internal bores in six places to identify tapered and or
oval conditions. Refer to Illustration 3.
1/30/24, 3:42 PM SIS 2.0
Shaft and Journal Diameters
Typical example of measuring an Outside Diameter (OD) Dimension.
To obtain the Dimension (F), measure the distance between Locations (D) and (E).
(C) Indicates the diameter of the shaft
(D) Shoulder of the shaft
(E) End of the shaft
(F) Indicates the overall measurable length of the shaft journal
Note: Measurements taken on the edge of a shaft may not give an accurate measurement.
Take measurements at locations (C1), (C2), and (C3).
Then take measurements at locations (C4), (C5), and (C6).
To ensure adequate life of the components, this document contains precise tolerances for measurements taken on various features. Ensure that several
sample measurements are taken at different locations on the same feature. Measure diameters of external shafts/ journals in six places to identify tapered
and or oval conditions. Refer to Illustration 4.
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
1/30/24, 3:42 PM SIS 2.0
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 C9.3 Engines
C9.3 Engine Water Pump Nomenclature.
(1) Hub
(2) Shaft
(3) Housing
(4) Seal
(5) Impeller
(6) Cover
Nomenclature for C13 Engines
C13 Engine Water Pump Nomenclature.
(1) Impeller
(2) Seal
(3) Shaft
(4) Housing
Nomenclature for C15 Engines
1/30/24, 3:42 PM SIS 2.0
PIP
202 1046 -
4
12: 01/3 666/ 4
Illustration 8
4
SEB 2:13+ 0 g07523057
© 2 F841 03:00
C15 Engine Water Pump Nomenclature.
(1) Gear
(2) Retainer
(3) Bearing
(4) Seal
0 8
(5) Shaft
2
(6) Seal
Ca3046, 4
(7) Housing
Nomenclature for 3044,

terp CEngines
and 3064
Con illa aterpi

fide r: llar
ntia Inc
l Ye .
llow
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
1/30/24, 3:42 PM SIS 2.0
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
3208 Front housing nomenclature.
(1) Bearing Bore
(2) Snap Ring Groove
(3) Pulley Face
(4) Ears
(5) Drain Hole
1/30/24, 3:42 PM SIS 2.0
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
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.
1/30/24, 3:42 PM SIS 2.0
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
Example of an earlier water pump
Later Water Pumps
1/30/24, 3:42 PM SIS 2.0
Example of a later water pump
Table 4
Water Pump Applications for 3600 Engines
Earlier Pump Part Number Later Pump Part Number Pump Type
7E-3172
1W-2548 304-4942 Fresh Water
457-5092
7E-8179
2W-0465 304-4948 Fresh Water
457-5098
7E-4358
304-4957
7W-0045 Sea Water
367-6095
480-7095
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 550 kPa (80 psi) to 620 kPa (90 psi) air pressure. Corrosion and debris can also
be removed from the housing with steel shot blast.
1/30/24, 3:42 PM SIS 2.0
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. An 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 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.
Inspection and Salvage Procedures
1/30/24, 3:42 PM SIS 2.0
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 C9 and C9.3 Engines
Typical example of C9.3 water pump housing.
Table 5
Seal and Shaft Bore Specifications for C9.3 Water Pump Housing
Part Number Diameter B Diameter C
36.462 ± 0.013 mm 38.036 ± 0.013 mm
557-9567
(1.4355 ± 0.0005 inch) (1.4975 ± 0.0005 inch)
1. Inspect all areas of the housing for cracks. Carefully inspect the flange areas by the bolt holes and the sealing surfaces.
2. Check the bearing and seal bores for pitting. Slight pitting in the bearing area is permitted, but not in the seal area.
Housing for C13 Engines
Typical example of C13 water pump housing.
Table 6
Bearing and Seal Bore Specifications for C13

Location Dimension
62.00 ± 0.025 mm
Diameter Y
(2.4409 ± 0.001 inch)
53.980 ± 0.030 mm
Diameter Z
(2.1252 ± 0.0012 inch)
Housing for C15 Engines
1/30/24, 3:42 PM SIS 2.0
Table 7
Bearing and Seal Bore Specifications for C15

Location Dimension
50.80 ± 0.025 mm
Diameter U
(2.00 ± 0.001 inch)
53.980 ± 0.03 mm
Diameter V
(2.1252 ± 0.0012 inch)
63.00 ± 0.50 mm
Diameter W
(2.4803 ± 0.0197 inch)
69.075 ± 0.013 mm
Diameter X
(2.7195 ± 0.0005 inch)
Housing for 3044, 3046, and 3064 Engines
Table 8
Housing for 3044, 3046, and 3064 Engines(1)
Bore Size (D) Bore Size (E)

52.000 + 0.018 − 0.012 mm 62.000 + 0.018 − 0.012 mm
(2.0472 + 0.0007 − 0.0005 inch) (2.4409 + 0.0007 − 0.0005 inch)
(1) The housing is nonserviceable. You must purchase the complete pump assembly if the housing is not reusable.
Housing for 3176 Engines
1/30/24, 3:42 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
4
SEB 2:13+ 0
© 2 F841 03:00
Table 9
Seal Diameters for Housing on 3176 Engines
0 8
Location Dimension
Diameter
D
Cat 4 C
53.98 ± 0.03 mm
2
(2.12519 ± 0.00118 inch)
e
Con rpilla aterpi
Diameter 36.445 ± 0.025 mm
E (1.43484 ± 0.00098 inch)
1. Inspect all areas of the housing for cracks. Carefully inspect the flange areas by the bolt holes and the sealing surfaces.
fide r: llar
2. Check the bearing and seal bores for pitting. Slight pitting in the bearing area is permitted, but not in the seal area.
ntia Inc
3. Examine the O-ring groove for pitting, scratches, or other damage. Do not reuse a housing that has a damaged O-ring groove.

l Ye .
llow
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".
Pits in the bearing bore.
Use again
1/30/24, 3:42 PM SIS 2.0
Gouges in the bearing bore.
Use again - after the raised (high) areas are removed with a half-round file.
Scratches in the bearing bore.
Use again
Damage to the snap ring groove.
Use again - after burrs are removed with a 6V-2010 Polishing Stone.
1/30/24, 3:42 PM SIS 2.0
Damage to the pulley face caused by forcing screws.
Use again
Nick on the edge of the housing.
Use again - after burrs on the gasket face are removed with a file.
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 3.0 mm (0.11811 inch).
Erosion (gradual wear) on the pilot diameter.
Use again
1/30/24, 3:42 PM SIS 2.0
Pits and scratches on the seal bore spotface.
Use again
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 2.0 mm (0.07874 inch).
Ear broken from the housing.
Use again - only if there is no damage to the web, and after the ear is welded.
1/30/24, 3:42 PM SIS 2.0
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 2.0 mm (0.07874 inch).
Housing Salvage Procedure for 3208 Engines

Salvage Broken Ears
A housing with a broken ear, as shown in Illustration 33, can still be used, if the web is not damaged. The salvage procedure is as follows:
Ear ground flat beyond the bolt hole.
1. Grind the broken ear flat beyond the hole as shown in Illustration 35.
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.
1/30/24, 3:42 PM SIS 2.0
2. Install the housing to the welding table with the broken ear over an aluminum plate, as shown in Illustration 36.
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.
3. Build up (add layers to) the ear with weld. Let the weld cool between each layer and remove weld slag before each application. See Illustration 37.
Note: Use a good quality welding rod made for cast iron welding with an AWS specification of ENi CI.
Gasket face of the ear.
4. Turn the housing over and fill the holes in the gasket face of the ear with weld. See Illustration 38. Correct any cracks with a V-groove filled with weld.
Follow the outer shape of the 9N-0137 Gasket as a guide to grind the ear to the correct shape.
5. Grind the gasket face smooth. Use a 9N-0137 Gasket as a guide for the shape of the ear. See Illustration 39.
1/30/24, 3:42 PM SIS 2.0
Ear and bolt face after grinding.
6. Grind the ear and bolt face. See Illustration 40.
The last step: drill a hole in the welded ear.
7. Use an FT–1732 Drill Fixture and a 10.71 mm (27/6 inch) drill bit to cut a hole in the welded ear.

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.
1/30/24, 3:42 PM SIS 2.0
Typical water pump seal bore locations
(A) Oil Seal Bore
(B) Water Seal Bore
Table 10
Seal Diameters for Housing on 3500 Engines

Location Dimension
Diameter 44.5 ± 0.03 mm
A (1.752 ± 0.001 inch)
B (1.287 ± 0.002 inch)
Typical water pump seal bore locations
(C) Oil Seal Bore
(D) Water Seal Bore
Table 11
Seal Diameters for Housing on 3516 and 3520 Engines

Location Dimension
1/30/24, 3:42 PM SIS 2.0
Diameter
42.85 ± 0.03 mm (1.6870 ± 0.0012 inch)
C
Diameter
50.80 ± 0.025 mm (2.0 ± 0.001 inch)
D

Earlier Housings
Table 12
Earlier Housing Dimensions for 3600 EnginesDimension
Location Description Dimension

2.5 ± 0.5 mm
F Depth of Bearing from Surface of Pump Housing
(0.10 ± 0.02 inch)
Diameter 64.957 ± 0.040 mm
Bearing Bore r
G (2.5574 ± 0.0016 inch)
Later Housings
Table 13
Later Housing Dimensions for 3600 Engines

112.5 ± 1 mm
F Installation Depth of Bearing
(4.43 ± 0.04 inch)
92.5 ± 1 mm
G Installation Depth of Bearing
(3.64 ± 0.04 inch)
20 ± 1 mm
H Installation Depth of Bearing
(0.79 ± 0.04 inch)
1/30/24, 3:42 PM SIS 2.0
Diameter 65.040 ± 0.040 mm

Front Bearing Bore
I (2.5606 ± 0.002 inch)
Diameter 89.080 ± 0.040 mm
Rear Bearing Bore
J (3.5070 ± 0.0016 inch)
Shaft for C9 and C9.3 Engines PIP

-
202 1046
12: 4 / 0 4 666
4 1 / 3
SEB :13+ 0
2
© 2 F841 03:00
Cat 024 C 8
C9 and C9.3 Engine Water Pump Shaft
(A) Impeller and water seal diameter
(B) Bearing diameter
(C) Pulley diameter
e r a
Table 14
Con illa terpi

Water Pump Shaft Specifications for C9 Engines
p
fide r: llar
Diameter 15.918 + 0.000 - 0.013 mm
Impeller and Water Seal
Inc
A (0.6267 + 0.00 - 0.0005 inch)
Diameter
B
Bearing
ntia
38.120 + 0.000 - 0.013 mm
.
(1.5008 + 0.00 - 0.0005 inch)
Diameter
C
Pulley / Hub
l Ye
18.961 + 0.000 - 0.013 mm
(0.7465 + 0.00 - 0.0005 inch)
Shaft for C13 Engines llow
Example of C13 water pump shaft.
Table 15

29.987 ± 0.008 mm
Diameter D
(1.1806 ± 0.0003 inch)
Minimum
Diameter E 19.10 mm
(0.7520 inch)
Shaft for C15 Engines
1/30/24, 3:42 PM SIS 2.0
Example of a C15 water pump shaft.
Table 16
30.022 ± 0.008 mm
Diameter F
(1.1820 ± 0.0003 inch)
Minimum
Diameter G 25.40 mm
(1.00 inch)
Shaft for 3044, 3046, and 3064 Engines
Table 17
Shaft for 3044, 3046, and 3064 Engines
Part Number Diameter A Diameter B

25.000 + 0.011 − 0.002 mm 13.000 + 0.000 − 0.015 mm
5I-7695
(0.9843 + 0.0004 − 0.0001 inch) (0.5118 + 0.0000 − 0.0006 inch)
178-6635 25.000 + 0.011 − 0.002 mm 15.500 + 0.000 − 0.013 mm
183-8233 (0.9843 + 0.0004 − 0.0001 inch) (0.6102 + 0.0000 − 0.0005 inch)
1/30/24, 3:42 PM SIS 2.0
Table 18
Flange for 3044, 3046, and 3064 Engines
Part Number Bore Size (F)

24.946 to 24.963 mm
5I-7696
(0.9821 to 0.9828 inch)
Shaft for 3176 Engines
3176 Engine Water Pump Shaft
(A) Bearing and Gear diameter
(B) Oil Seal diameter
(C) Impeller and Water Seal diameter
Table 19
Shaft Dimensions for 3176 Engines
Location Description Measurement

Diameter 29.987 ± 0.008 mm
Bearing and Gear
A (1.18059 ± 0.00031 inch)
Oil Seal
B (1.25984 ± 0.01969 inch)
Diameter 15.912 ± 0.006 mm
Impeller and Water Seal
C (0.62646 ± 0.00024 inch)

Nomenclature
1/30/24, 3:42 PM SIS 2.0
3208 Engine Water Pump Shaft
(14) Bearing diameter
(15) Seal diameter
(16) Bearing shoulder
(17) Pulley end.
Remove debris and corrosion from the shaft with a 8T-7748 Polishing Wheel.
NOTICE
Use the 8T-7748 Polishing Wheel only. Other polishing wheels
can remove too much material and damage the shaft.
Scratch along the length of the seal diameter.
Use again - only if the scratch can be removed with a 8T-7748 Polishing Wheel.
1/30/24, 3:42 PM SIS 2.0
Groove near the pulley end of the bearing diameter.
Use again
Wear step along the circumference of the bearing diameter.
Do not use again

After cleaning and if necessary polishing dimensional checks of the water pump shaft. Refer to Table 20 for the critical dimensions.
Former style shafts with tapered area.
The former style shafts as shown in Illustration 57 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 57. 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 58,59, and 60.
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.
1/30/24, 3:42 PM SIS 2.0
1. Measure the critical diameters. Refer to Illustrations 58,59, and 60 to find the applicable shaft style.
Current style shafts have critical dimensional areas to check. The critical areas are called out in Illustrations 58,59, and 60. Also, refer to Table 20 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.
2. Measure runout. Refer to Table 20 for the correct diameters related to the applicable shaft.
Measure runout where referenced in Table 20. 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.
Table 20
Water Pump Shaft Reuse Specifications for 3500 Engines
Shaft Part
A B C D (1)
E
Number
Diameter Diameter
Diameter Diameter
31.75 ± 0.08 mm 19.05 ± 0.013 mm
25.0 ± 0.5 mm 28.160 ± 0.013 mm
(1.250 ± 0.003 inch) (0.7500 ± 0.0005 inch)
5N-4384 N/A (0.98 ± 0.02 inch) (1.1087 ± 0.0005 inch)
Runout Runout
Runout Runout
0.05 mm 0.05 mm
N/A N/A
(0.002 inch) (0.002 inch)
Diameter Diameter
Diameter Diameter
31.75 ± 0.08 mm 19.05 ± 0.013 mm
25.0 ± 0.5 mm 28.00 ± 0.25 mm
(1.250 ± 0.003 inch) (0.7500 ± 0.0005 inch)
212-8178 N/A (0.98 ± 0.02 inch) (1.102 ± 0.010 inch)
Runout Runout
Runout Runout
0.05 mm 0.05 mm
N/A N/A
(0.002 inch) (0.002 inch)
Diameter Diameter Diameter
Diameter Diameter
43.00 ± 0.02 mm 31.75 ± 0.08 mm 25.400 ± 0.013 mm
41.00 ± 1.50 mm 47.00 ± 0.02 mm
(1.693 ± 0.001 inch) (1.250 ± 0.003 inch) (1.000 ± 0.001 inch)
212-8180 (1.614 ± 0.060 inch) (1.850 ± 0.001 inch)
Runout Runout Runout
Runout Runout
0.05 mm 0.05 mm 0.05 mm
N/A N/A
(0.002 inch) (0.002 inch) (0.002 inch)
Diameter Diameter
Diameter Diameter
235-4539 27.00 ± 0.08 mm 25.40 ± 0.01 mm
31.03 ± 0.18 mm 33.325 ± 0.025 mm
258-8726 (1.063 ± 0.003 inch) (1.00000 ± 0.00 inch)
N/A (1.222 ± 0.007 inch) (1.312 ± 0.001 inch)
263-1052 Runout Runout
Runout Runout
428-8019 0.05 mm 0.05 mm
N/A N/A
(0.002 inch) (0.002 inch)
Diameter Diameter
Diameter Diameter
34.00 ± 0.08 mm 31.750 ± 0.013 mm
31.03 ± 0.18 mm 40.010 ± 0.025 mm
(1.339 ± 0.003 inch) (1.2500 ± 0.0005 inch)
381-7343 N/A (1.222 ± 0.007 inch) (1.5752 ± 0.0010 inch)
Runout Runout
Runout Runout
0.05 mm 0.05 mm
N/A N/A
(0.002 inch) (0.002 inch)
1/30/24, 3:42 PM SIS 2.0
Diameter Diameter
Diameter Diameter
31.75 ± 0.08 mm 19.05 ± 0.013 mm
25.00 ± 0.05 mm 28.160 ± 0.013 mm
(1.250 ± 0.003 inch) (0.7500 ± 0.0005 inch)
430-9695 N/A (0.984 ± 0.002 inch) (1.1087 ± 0.0005 inch)
Runout Runout
Runout Runout
0.05 mm 0.05 mm
N/A N/A
(0.002 inch) (0.002 inch)
Diameter Diameter
Diameter Diameter
27.00 ± 0.08 mm 25.40 + 0.01 -0.00 mm
31.03 ± 0.18 mm 33.325 ± 0.025 mm
(1.063 ± 0.003 inch) (1.00000 ± 0.00 inch)
493-9609 N/A (1.222 ± 0.007 inch) (1.312 ± 0.001 inch)
Runout Runout
Runout Runout
0.05 mm 0.05 mm
N/A N/A
(0.002 inch) (0.002 inch)
(1) The oil seal diameter can be machined 0.025 mm (0.001 inch) undersized.
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
Table 21
Earlier Shaft Dimensions for 3600 Engines

12 ± 0.05 mm
A Width of Groove in Shaft
(0.472 ± 0.002 inch)
44.45 ± 0.20 mm
B Shaft Diameter at Surface of Carbon Seal
(1.750 ± 0.008 inch)
64.85 ± 0.020 mm
C Diameter of Impeller Shaft
(2.553 ± 0.0008 inch)
44.88 ± 0.02 mm
D Diameter of Support End of Shaft
(1.767 ± 0.0008 inch)
1/30/24, 3:42 PM SIS 2.0
Table 22
Earlier Plate Dimensions for 3600 Engines

11.85 ± 0.05 mm
E Width of the Plate
(0.46653 ± 0.00197 inch)
Fresh water shaft support
Sea water shaft support
Table 23
Earlier Shaft Support Dimensions for 3600 Engines

2.5 ± 0.5 mm
I Depth of Bearing from Surface of Support
(0.10 ± 0.02 inch)
51 ± 0.02 mm
H Support Bore Diameter
(2.00 ± 0.001 inch)
1/30/24, 3:42 PM SIS 2.0
PIP
-
202 1046
4
12: 01/3 666
/ 4
4
SEB 2:13+ 0
© 2 F841 03:00
Cat 024 C 8
Table 24
e a
Earlier Shaft End Play Dimension for 3600 Engines
Number Description
r
Con illa terpi
pMeasurement
llar
0.05 mm
fide r:
(0.002 inch)
J End play of Impeller Shaft
to 0.25 mm
Inc
(0.010 inch)
Later Shafts ntia .

l Ye
llow
Table 25
Later Shaft Dimensions for 3600 Engines
Number Description Measurement

12 ± 0.05 mm
A Width of Groove in Shaft
(0.472 ± 0.002 inch)
44.45 ± 0.20 mm
B Shaft Diameter at Surface of Carbon Seal
(1.750 ± 0.008 inch)
64.85 ± 0.020 mm
C Diameter of Impeller Shaft
(2.553 ± 0.0008 inch)
88.878 ± 0.013 mm
D Diameter of Support End of Shaft
(3.4991 ± 0.0005 inch)
1/30/24, 3:42 PM SIS 2.0
Table 26
Later Shaft Dimensions for 3600 Engines
Number Description Measurement

11.85 ± 0.05 mm
E Width of the Plate
(0.46653 ± 0.00197 inch)
Table 27
Later Shaft End Play Dimension for 3600 Engines
Location Description Measurement

0.05 mm
(0.002 inch)
K End play of Impeller Shaft
to 0.25 mm
(0.010 inch)
Impeller for C9 and C9.3 Engines
Impeller for C-9 and C9 Engines
(9) Impeller blades
1. The outside tip of impeller blades (9), should not have any grooves, scratches, or erosion.
2. 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.
3. 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 be 15.885 mm (0.62539 inch).
4. 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.
5. 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.
6. If the red end of the gauge fits through the impeller bore, do not use the impeller again.
1/30/24, 3:42 PM SIS 2.0
7. 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.
Cogsdill KBN-625 Knurling Tool.
The salvage procedure is as follows:
1. Turn the adjustment screw of the Cogsdill KBN-625 Knurling Tool. until the distance across the roll is 16.433 mm (0.64697 inch).
Knurl the bore at approximately 265 rpm 0.254 mm/revolution (265 rpm .010"/revolution).
2. 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.
3. After the knurling procedure, use a plug gauge to check that the bore dimension is correct.
4. 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
1/30/24, 3:42 PM SIS 2.0
Table 28
Impeller for 3044, 3046, and 3064 Engines
Diameter
Part Number
C
13.000 + 0.047 − 0.062 mm
5I-7694
(0.5118 + 0.0019 − 0.0024 inch)
15.500 + 0.035 − 0.062 mm
178-6634
(0.6102 + 0.0014 − 0.0024 inch)
Impeller for 3176 Engine
Impeller
(12) Seal face
(13) Impeller blades
1. The outside tip of impeller blades (13), should not have any grooves, scratches, or erosion.
2. 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.
3. Inspect seal face (12) for pitting, erosion, and scratches. If there is any damage to the seal face, the impeller must be replaced.
4. 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 be 15.985 mm (0.62933 inch).
5. 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.
6. 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.
7. If the red end of the gauge fits through the impeller bore, do not use the impeller again.
8. 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.
1/30/24, 3:42 PM SIS 2.0
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.
1/30/24, 3:42 PM SIS 2.0
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 77. (One end of the plug gauge is
green and has a 15.870 mm (0.62480 inch) diameter, the other end is red and has a 15.962 mm (0.62842 inch) diameter.
1. 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.
2. 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.
3. If the red end of the gauge does fit through the impeller bore, do not use the impeller again.
4. 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 78. If this distance is more than 15.88 mm
(0.62520 inch). If this distance is less than 15.88 mm (0.62520 inch), do not use the impeller again.
Also, measure blade from leading edge to trailing edge. See Illustrations 78 through 79. If this dimension is less than 4.76 mm (0.18740 inch) at any
location, do not use the impeller again.
NOTICE
Impellers with blade wear must be installed with an FT–1704
Impeller installer to give acceptable performance.
Measure the blade height.
Tip erosion is within the "Use again minimum" dimension.
(A) Leading Edge
(B) Trailing Edge
1/30/24, 3:42 PM SIS 2.0
Use again - if the dimension is greater than 4.76 mm (0.18740 inch) from the leading edge to the trailing edge.
Some tip erosion but area of tip is greater than the "Use again minimum" dimension.
Use again
Tip erosion greater than the "Use again minimum" dimension.
Do not use again
Wear step on the back face of the impeller.
Use again
1/30/24, 3:42 PM SIS 2.0
Damage to the shaft bore.
Use again
Erosion of blades.
Do not use again
Face damage.
Do not use again
1/30/24, 3:42 PM SIS 2.0
Porosity.
Do not use again
Groove in blade tip (C) and back plate wear (D).
Do not use again
Crack in a blade.
Do not use again
1/30/24, 3:42 PM SIS 2.0
PIP
-
202 1046
12: 4 / 0 4 666
4 1 / 3
Illustration 89
Broken blade.
SEB :13+ 0
g06280593 2
© 2 F841 03:00
Do not use again

Bore Salvage 0
Cat 4 C2 8
e
Con rpilla aterpi
The purchase of the special tool that this procedure needs is practical only if approximately 20 impellers can be salvaged.
fide r: llar
ntia Inc
Illustration 90
g06280597
l Ye .
llow
1/30/24, 3:42 PM SIS 2.0
4. 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.
Remove the burrs from blade edges when grinding blade tips.
1/30/24, 3:42 PM SIS 2.0

Impeller Visual Inspection
(1) Impeller Blade
(2) Seal Face
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 97. 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.
1/30/24, 3:42 PM SIS 2.0
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 texture specifications if it is to be reused without machining. The impeller bore (B) must be
within −.05 ± 0.013 mm (0.0020 ± 0.0005 inch) larger than the shaft diameter. Refer to Illustration 98 for the location of the critical bore areas and Table 29
for the critical diameters. Inspect and note the diameter of bore (A) and bore (B).
(A) Seal bore diameter
(B) Shaft bore diameter
Table 29
Water Pump Impeller Bore Specifications for 3500 Engine
Seal Bore Diameter Shaft Bore Diameter Salvaged Bore Diameter

Part Number
A B C
7W-5769 34.30 ± 0.50 mm (1.350 ± 0.020 inch) 15.34 ± 0.08 mm (0.604 ± 0.003 inch) N/A
34.3 ± 0.51 mm 19 ± 0.013 mm
212-8181 N/A
(1.350 ± 0.020 inch) (0.7480 ± 0.0005 inch)
34.3 ± 0.51 mm 19 ± 0.013 mm 19 ± 0.013 mm
212-8183
(1.350 ± 0.020 inch) (0.7480 ± 0.0005 inch) (0.7480 ± 0.0005 inch)
42.9 ± 0.5 mm 25.342 ± 0.013 mm 25.315 ± 0.02 mm
212-8184
(1.69 ± 0.020 inch) (0.9977 ± 0.0005 inch) (0.9967 ± 0.0008 inch)
42.9 ± 0.5 mm 25.342 ± 0.013 mm
212-8186 N/A
(1.69 ± 0.020 inch) (0.9977 ± 0.0005 inch)
42.9 ± 0.5 mm 25.342 ± 0.013 mm 25.315 ± 0.02 mm
212-8187
(1.69 ± 0.020 in) (0.9977 ± 0.0005 inch) (0.9967 ± 0.0008 inch)
42.9 ± 0.5 mm 25.35 ± 0.012 mm
235-4541 N/A
(1.69 ± 0.020 inch) (0.9980 ± 0.0005 inch)
48.6 ± 0.5 mm 31.705 ± 0.013 mm
268-1846 N/A
(1.91 ± 0.02 inch) (1.2482 ± 0.0005 inch)
25.35 ± 0.012 mm
258-8727 N/A N/A
(0.9980 ± 0.0005 inch)
25.344 ± 0.012 mm
493-9610 N/A N/A
(0.10 ± 0.0005 inch)

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.
1/30/24, 3:42 PM SIS 2.0
Critical dimensions for machining the bore
(A) Angle of chamfer: 25°
(B) Depth of chamfer: 1.25 ± 0.25 mm (0.049 ± 0.010 inch)
(C) Diameter of bore
1. Machine the impeller bore (C) to the specification listed in Table 29.
2. Machine the chamfer on the top face of the impeller to 25° and 1.25 ± 0.25 mm (0.049 ± 0.010 inch) deep.
3. De-burr the sharp edges as needed after machining the bore.
4. The surface texture of the impeller bore should be inspected. The finish should measure 0.8 microns to be acceptable.
5. After machining the impeller bore, it must be balanced. Refer to the section "Impeller Balancing" within this document.
If the impeller bore measures less than the minimum size listed in Column (B) of Table 29, 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:
1. Refer to Column (C) of Table 29 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 29. 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.

Example of Caterpillar Inc CNC knurling tooling.
2. 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
1/30/24, 3:42 PM SIS 2.0

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.

Critical balancing dimensions
(A) Radius to drill balancing holes.
(B) Minimum spacing between balancing holes.
(C) Balancing hole.

(B) Minimum spacing between balancing holes.
(C) Balancing hole.
1/30/24, 3:42 PM SIS 2.0

(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 30. Refer to Illustrations 102,103, and 104.
Table 30
Water Pump Impeller Balancing Specifications for 3500 Engines
Impeller Part Number Balance Hole Radius Max. Bit Diameter Max. Bit Depth Min. Spacing
212-8181 45.0 mm 7.0 mm 3.81 mm 1.5 mm
212-8183 (1.77 inch) (0.276 inch) (0.15 inch) (0.059 inch)
212-8184
94.80 ± 0.75 mm 13.0 mm 3.0 mm 3 mm
212-8186
(3.73 ± 0.030 inch) (0.50 inch) (0.12 inch) (0.12 inch)
212-8187
81.25 ± 0.75 mm 9.5 mm 8.5 mm 1.5 mm
235-4541
268-1846 75.25 ± 0.75 mm 9.5 mm 8.5 mm 1.5 mm
390-6235 (2.963 ± 0.030 inch) (0.374 inch) (0.335 inch) (0.059 inch)
67.75 ± 0.75 mm 9.5 mm 8.5 mm 1.5 mm
313-2760
81.25 ± 0.75 mm 9.5 mm 8.5 mm 1.5 mm
493-9610
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.
Table 31
New and Corresponding Former Water Pump Groups for 3500 Engines
Current Water Pump Previous Water Pumps Housing Assemblies Housing Number
156-9817
212-8167(1) (2)(3)(4) 156-9849 156-9823
424-3625(1) 291-4311(3)(4)(5) 291-4309 291-4308

424-3628(1) 291-4312(3)(4)(5) 291-4309 291-4308
291-4313 (4)(5)
424-3629(1) 291-4309 291-4308
317-5901(4)(5)
416-0606(1) 212-8172(4) 2W-7777 2W-7639
212-8173 (4)
416-0607(1) 166-4379(3)(4) 7N-4756 8N-1005

122-0502(3)(4)
212-8175(4)
416-0608(1) 166-4380(3)(4) 2W-7777 2W-7639
122-0503(3)(4)
1/30/24, 3:42 PM SIS 2.0
212-8176 (4)
2W-9726(4)(5)
416-0609(1) 7N-4756 8N-1005
166-4377(3)(4)
122-0501(3)(4)
212-8177(4)
2W-9729(4)
416-0610 (1)
7N-4756 8N-1005
166-4378(3)(4)
122-0500(3)(4)
416-0611(1) 250-6721(4) 250-6723 250-6725
416-0612(1) 312-0964(4) 250-6723 250-6725
313-2650 (4)
212-8174(4) 137-8217
416-0613(1) 137-8241
166-4382(3)(4) 313-2651
137-8242(3)(4)
416-0614(1) 350-8955(4) N/A N/A
235-4536 (1)
221-5353 (4)
206-4279 206-4279
221-5352 (4)
349-6213(1) 235-4535(4) 206-4278 206-4278

258-8725(4)
315-5137 8N-8465
(2)(3)(4)(5) (2)(3)(4)(5) 8N-8464 8N-8454
New Ring Assembly New Seal Group Former Seal Group

124-5245
166-4374 416-0603 166-4376
416-0603
(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.

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 2.5 ± 0.05 mm (0.09843 ± 0.00197 inch) diameter spring pin hole through the water pump housing as shown in Illustration 11. To drill
this hole properly, the following drill fixture may be fabricated to align the drill hole accurately. Refer to Illustration 106 for dimensions.
1/30/24, 3:42 PM SIS 2.0
PIP
202 -1046
12: 4 / 0 4 666
4 1 / 3
SEB :13+ 0
2
© 2 F841 03:00
0
Cat 4 C 2 8
Illustration 106
Table 32
e r
Con illa terpi
p
g06281533
a
Fixture Dimensions for 3500 Engines
fide r: llar
Location Dimension
ntia Inc
.
A 5/16 - 18
Diameter
B
12.7 mm (0.5 inch)
Three Places
l Ye
C
D
E
20.6 mm (0.811 inch)
12.7 mm (0.5 inch)
17.5 mm (0.689 inch)
llow
F 37.0 mm (1.45 inch)
G 55.6 mm (2.189 inch)
H 33.80 mm (1.330 inch)
50.80 mm (2 inch)
I
Radius
J 1.52 mm (0.06 inch) x 45°
K 15.875 mm (0.625 inch)
The following illustration shows the location of the new hole in the housing assembly if you choose not to use the fixture.

The hole needs to be 2.5 ± 0.05 mm (0.09843 ± 0.00197 inch) on a radius of 17.5 ± 0.25 mm (0.689 ± 0.001 inch) (L).
1/30/24, 3:42 PM SIS 2.0

(M) Drilling fixture positioned onto the water pump housing
(P) Hole in housing that was drilled
Table 33
Tooling Required for 3500 Engines
Location Qty Description

N 1 1A-LS-Lock Screw
O 1 L-32-12 5/16 ID Liner Bushing
SF-20-22 .0985 ID Drill Bushing
Q 1
28.44800 mm (1.12 inch) Long
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.
1/30/24, 3:42 PM SIS 2.0
Seal angle for a 212-8179 Shaft.

Seal angle for a 430-9695 Shaft.
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 109 and 110 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.

(1) Sleeve Bearing
(2) Thrust Washer
1/30/24, 3:42 PM SIS 2.0

Example of a hydraulic sleeve bearing puller.
Some pumps have a sleeve bearing (1) installed refer to Illustration 111. 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 113 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 113 and 114 for an example of a supported water pump.

Support plate used for removal of the shaft.
(A) 38 mm (1.496 inch)
(B) 133.4 mm (5.252 inch)
(C) 382 mm (15.039 inch)
(D) 305 mm (12.008 inch)

Water pump successful disassembly.
1/30/24, 3:42 PM SIS 2.0
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.
1. Install plugs.
2. Install the oil seal.
3. Lubricate the shaft with clean water. Then insert the shaft and thrust washers. Tighten the thrust washer bolts.
4. If a bearing sleeve was removed, install a new bearing sleeve.
5. 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.
6. 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.
7. 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

Typical example of C27 and C32 water pump housing.
Table 34
1/30/24, 3:42 PM SIS 2.0
C27 and C32 Housing Acceptable Dimensions and Tolerances for Thermal Spray
Section Z-Z
Part Diameter Diameter Diameter Diameter
E F
Number A B C D
216-0657 120.57 ± 0.03 mm 69.075 ± 0.013 mm 40.00± 0.025 mm 184.28 ± 0.05 mm 37.60 ± 0.10 mm 34.66 ± 0.25 mm
352-0202 (4.747 ± 0.001 inch) (2.7195 ± 0.0005 inch) (1.5748 ± 0.0010 inch) (7.255 ± 0.002 inch) (1.480 ± 0.004 inch) (1.365 ± 0.010 inch)
352-0200 NOT SERVICEABLE
116.86 ± 0.05 mm 104.00 mm 41.275 ± 0.05 mm 209.42 ± 0.10 mm 7.00 mm 37.00 ± 0.25 mm
416-0610
(4.6008 ± 0.0020 inch) (4.0945 inch) (1.6250 ± 0.0020 inch) (8.2449 ± 0.0040 inch) (0.2756 inch) (1.4567 ± 0.010 inch)
116.86 ± 0.05 mm 104.00 mm 41.275 ± 0.05 mm 209.42 ± 0.10 mm 7.00 mm 37.00 ± 0.25 mm
416-0613
(4.6008 ± 0.0020 inch) (4.0945 inch) (1.6250 ± 0.0020 inch) (8.2449 ± 0.0040 inch) (0.2756 inch) (1.4567 ± 0.010 inch)
120.57 ± 0.03 mm 69.075 ± 0.013 mm 40.00 ± 0.025 mm 184.28 ± 0.05 mm 37.60 ± 0.10 mm 34.66 ± 0.25 mm
468-4839
(4.747 ± 0.001 inch) (2.7195 ± 0.0005 inch) (1.5748 ± 0.0010 inch) (7.255 ± 0.002 inch) (1.480 ± 0.004 inch) (1.365 ± 0.010 inch)
244.90 ± 0.03 mm 81.00 ± 0.015 mm 40.005 ± 0.025 mm 149.225 ± 0.025 mm 28.5 ± 0.13 mm 30.50 ± 0.50 mm
540-4708
120.57 ± 0.03 mm 69.075 ± 0.013 mm 40.00 ± 0.025 mm 174.63 ± 0.05 mm 30.74 ± 0.20 mm 34.66 ± 0.25 mm
541-2494
Table 35
C27 and C32 Housing Acceptable Dimensions and Tolerances for Thermal Spray
Detail Y-Y
Part
G H J K L
Number
216-0657 6.86 ± 0.25 mm 2.84 ± 0.13 mm 4.11 ± 0.13 mm R 1.0 ± 0.5 mm R 0.80 ± 0.20 mm
352-0202 (0.270 ± 0.010 inch) (0.112 ± 0.005 inch) (0.162 ± 0.005 inch) (2.0 (0.04 ± 0.02 inch) (0.031 ± 0.008 inch)
6.86 mm 2.84 ± 0.13 mm 4.11 ± 0.13 mm R 1.0 ± 0.5 mm R 0.80 ± 0.20 mm
395-3467
(0.2701 inch) (0.112 ± 0.005 inch) (0.162 ± 0.005 inch) (2.0 (0.04 ± 0.02 inch) (0.031 ± 0.008 inch)
Maximum of R
10.00 mm
416-0610 N/A N/A N/A 1.00 mm
(0.3937 inch)
(0.0394 inch)
Maximum of R
10.00 mm
416-0613 N/A N/A N/A 1.00 mm
(0.3937 inch)
(0.0394 inch) x 45°
6.86 ± 0.25 mm 2.84 ± 0.13 mm 4.11 ± 0.13 mm R 1.0 ± 0.5 mm R 0.80 ± 0.20 mm
468-4839
(0.270 ± 0.010 inch) (0.112 ± 0.005 inch) (0.162 ± 0.005 inch) (2.0 (0.04 ± 0.02 inch) (0.031 ± 0.008 inch)
2.65 ± 0.13 mm
15.00 ± 0.25 mm (0.1043 ± 0.0051 inch) Depth of O-ring 4.95 ± 0.10 mm R 0.80 ± 0.25 mm R 0.80 ± 0.20 mm
540-4708
(0.5906 ± 0.0098 inch) groove on adjacent surface to what is (0.1949 ± 0.0039 inch) (0.0315 ± 0.0098 inch) (0.0315 ± 0.0079 inch)
shown in Detail Y-Y.
6.86 mm 2.64 ± 0.13 mm 4.75 ± 0.13 mm R 0.80 ± 0.20 mm R 1.00 ± 0.50 mm
579-5381
(0.2701 inch) (0.1039 ± 0.0051 inch) (0.1870 ± 0.0051 inch) (0.0315 ± 0.0079 inch) (0.0394 ± 0.0197 inch)
Part Description
Table 36
Base Metal Gray Iron Casting
Hardness 187-241 BHN
Arc Spray Equipment and Procedure

Table 37
Maximum Surface Texture 0.8 µm (31.4961 µinch)

Reason for Spraying Wear, grooving, or corrosion
Mating Part Contact Area & Material Engine cover and o-ring
Arc Spray Equipment Type SmartArcby Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU
Wire TAFA 30T Wire Top Coat, TAFA 75B Bond Coat
1/30/24, 3:42 PM SIS 2.0
Finish Thickness As required

Spray Angle 90°
Substrate Pre-Heat Temperature 66 °C (150 °F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed 148 °C (300 °F)
Auxiliary Cooling Filtered shop air
Rotation/Traverse Device Lathe
Rotation Speed 92.0 SMPM (300.00 SFPM)
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)
Table 38
Arc Spray Procedure Check List

Clean Part Degrease in hot caustic solution
Undercut If desired
Chamfer If required - 0.8 mm (0.032 inch) x 45°
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 690 kPa (100.0 psi)
Blast Nozzle to Work Distance 51 to 150 mm (2.0 to 6.0 inch)
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 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 Distance (Standoff) 128 mm (5.0 inch) 128 mm (5.0 inch)
Spray Rate/Bond Pass 0.038 mm (0.0015 inch)/pass 0.038 mm (0.0015 inch)/pass
Consumable (Topcoat) TAFA 30T TAFA 30T
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 Distance (Standoff) 166 mm (6.5 inch) 166 mm (6.5 inch)
Spray Rate/Build Up 0.058 mm (0.0023 inch)/pass 0.058 mm (0.0023 inch)/pass
Rotation Speed of Part 92.0 SMPM (300.00 SFPM)
Traverse Rate of Gun 11.0 SMPM (40.00 SFPM)
Gun Fixturing Method Machine mount or hand held
Finishing Equipment Milling machine
Part/Cutter Rotation Roughing 50.0 SMPM (150.00 SFPM)
Part/Cutter Rotation Finishing 75.0 SMPM (250.00 SFPM)
Coolant Oil base synthetic - 40:1 ratio
Traverse Speed 0.30 mm (0.012 inch)
Depth of Rough Cut 0.51 mm (0.020 inch)
1/30/24, 3:42 PM SIS 2.0
Depth of Finish Cut 0.25 mm (0.010 inch)
Flame Spray Equipment and Procedure

Table 39

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 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 flame on area to be sprayed
Auxiliary Cooling If desired
Rotation/Traverse Device 91.4 SMPM (300.00 SFPM)
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
Table 40
Flame Spray Process (6P) Procedure Check List

Undercut To "tru-up" surface
Chamfer If required - 0.8 mm (0.032 inch) x 45°
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 690 kPa (100.0 psi)
Blast Nozzle to Work Distance 51 to 150 mm (2.0 to 6.0 inch)
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 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 230 mm (9.0 inch)
1/30/24, 3:42 PM SIS 2.0
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 Lathe or Horizontal Mill
Part/Cutter Rotation 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 cloth for desired finish
Thermal Spray Procedures for Water Pump Housing Bore on 3208 Engines

Table 41
Part Number Dimension A Dimension B

9N-3076 69.019 mm ±0.02 (2.71728 inch ±0.00079) 50.98 mm ±0.25 mm (2.00708 inch ±0.00984 in)
Part Description
Table 42
Base Metal Cast Iron

Hardness N/A

Table 43

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 0.64 mm (0.025 inch) per side
Spray Angle 81° to bore
Substrate Pre-Heat Temperature 38 °C (100 °F)
Rotation/Traverse Device Lathe or turntable
Rotation/Traverse Speed 92 SMPM (300.00 SFPM)
Surface Preparation Method Grit blast
1/30/24, 3:42 PM SIS 2.0
Machining Equipment Type Lathe

Recommended Cutter Grade C-2 carbide 0.79 mm (0.031 inch) radius
Remarks
Table 44
PIP
Flame Spray Process (6P-II) Procedure
Clean Part -
202 1046
Wash in non-oil base solvent
Check List
4
Undercut Not required
Chamfer
Remove Oxide 4
12: 01/3 666
/
All edges - 45° x 0.76 mm (0.030 inch)
Emery paper or glass beading
Mask for Blast
Blast Equipment
Grit Type and Size
4
SEB 2:13+ 0
Metal mask 61.994 ± 0.020 x 2.5 mm (2.4407 ± 0.0008 x .1 inch) thick
Pressure blast
G-25 angular steel
© 2 F841 03:00
Blast Nozzle to Work Distance 51 mm (2.0 inch)
0 8
Remove Blast Mask Remove
Mask for Spray
Spray Equipment Type
Cat 4 C2
Use METCO Anti-Bond - Install snap ring in groove
6P-II
Nozzle
Air Capacity/Pressure e
Con rpilla aterpi
6P7C-K "K"
6P-3/Cooling Air - 140 kPa (20.0 psi)
llar
Oxygen Flow
fide r:
1190 L/h (42.0 cfh)
ntia Inc
Carrier Gas Pressure
Carrier Gas Flow
l Ye
380 kPa (55.0 psi)
1050 L/h (37.0 cfh) .
Spray Rate/Build Up
Gun to Work Distance
Rotation Speed of Part (RPM)
229 mm (9.0 inch)
470
llow
5.5 kg (12.00 lb) per hour 0.10 to 0.15 mm (0.004 to 0.006 inch)
Rotation Speed of Part 92 SMPM (300.00 SFPM)

Traverse Rate of Gun 15 SMPM (50.00 SFPM)
Gun Fixturing Method Hand held or machine mount
Bond Pass/Thickness 0.08 to 0.13 mm (0.003 to 0.005 inch)
Top Coat/Thickness As required
Finishing Equipment Lathe
Part/Cutter Rotation 61 SMPM (200.00 SFPM)
Traverse Speed 0.08 mm (0.003 inch) per revolution
Depth of Rough Cut 0.25 - 0.51 mm (0.010 - .020 inch)
Depth of Finish Cut 0.25 mm (0.010 inch)
Note: Do not direct flame on area to be sprayed.
Thermal Spray Procedures for Water Pump Shaft on D348, D398, G398, and
D399 Engines
1/30/24, 3:42 PM SIS 2.0

Table 45
Part Number Diameter A (Bearing) Diameter B (Seal)

5N-4378 32.13 ± 0.05 mm (1.265 ± 0.002 inch) 25.45 ± 0.05 mm (1.002 ± 0.002 inch)
Part Description
Table 46
Base Metal Alloy Steel

Hardness RC 45 min

Table 47
Diameter A: 0.25 - 0.51 µm (9.84252 - 20.07874 µinch)

Surface Texture
Diameter B: 0.51 - 2.54 µm (20.07874 - 100.000 µinch)
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 0.51 mm (0.020 inch)
Spray Angle 90°
Substrate Pre-Heat Temperature N/A
Auxiliary Cooling A J Siphon
Rotation/Traverse Speed 91.4 SMPM (300.00 SFPM)
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
Table 48
1/30/24, 3:42 PM SIS 2.0
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
Mask for Blast Use metal mask or duct tape
Blast Equipment Suction blast cabinet
Grit Type and Size METCOLITE C
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 - 170 kPa (25.0 psi)
Extension N/A
Air Jets/Pressure N/A
Spray Rate/Bond Pass N/A
Spray Rate/Build Up 5.5 kg (12.00 lb) per hour 0.10 - 0.15 mm (0.004 - 0.006 inch) per pass
Traverse Rate of Gun 15 SMPM (50.00 SFPM)
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 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 D9H Water Pump Housing
1/30/24, 3:42 PM SIS 2.0

Table 49
4M-2281 Housing ( 6N-6424 Water Pump Gp) Dimensions

A 108.2 ± 0.05 mm (4.26 ± 0.020 inch)
B 169.012 ± 0.025 mm (6.654 ± 0.001inch)
C 96.56 ± 0.064 mm (3.8015 ± 0.0025 inch)
D 139.75 ± 0.25 mm (5.562 ± 0.010 inch)
Part Description
Table 50
Base Metal Gray Iron

Hardness -

Table 51
Maximum Surface Texture 140 µinches

Reason for Spraying Erosion
Mating Part Contact Area & Material Impeller, Cover
Metco Equipment Type Metco 6P-II
Metco Material 453
Finished Thickness As Required 0.25 to 0.38 mm (0.010 to 0.015 inch)
Finishing Allowance 0.51 to 0.64 mm (0.020 to 0.025 inch)
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
148 °C (300 °F)
Exceed
Auxiliary Cooling AJ, If desired
Rotation/Traverse Device Lathe or Turntable
Rotation/Traverse Speed 91.4 SMPM (300.00 SFPM)
Hand grind erosion before grit blasting. Grinding removes contamination. Undercut (machine) wear
Surface Preparation Method
surface area.
1/30/24, 3:42 PM SIS 2.0
Machine Equipment Type Lathe

Recommended Cutter Grade C2, 883 Carboloy, or equivalent
Table 52

Undercut 0.51 mm (0.020 inch) to "tru-up" surface
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
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 140 - 170 kPa (20.0 - 25.0 psi)
Spray Rate/Build Up 5.5 kg (12 lb) per hour or 90 gm (3.2 oz) per min
Rotation Speed of Part (RPM) 165 RPM
Gun Fixturing Method Hand Held
Top Coat/Thickness 0.10 to 0.15 mm (0.004 to 0.006 inch) per pass
Finishing Equipment Lathe
Part/Cutter Rotation 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
Salvage Welding
Personal injury or death can result from fumes, gases and

ultraviolet rays from the weld arc.
Welding can cause fumes, burn skin and produce ultraviolet

rays.
Keep your head out of the fumes. Use ventilation, exhaust at the
arc, or both, to keep fumes and gases from your breathing area.
Wear eye, ear and body protection before working.
Protect yourself and others; read and understand this warning.

Fumes and gases can be dangerous to your health. Ultraviolet
rays from the weld arc can injure eyes and burn skin. Electric
shock can cause death.
1/30/24, 3:42 PM SIS 2.0
Read and understand the manufacturer's instructions and your
employer's safety practices. Do not touch live electrical parts.
See "American National Standard Z49.1, Safety in Welding and

Cutting" published by the American Welding Society.
American Welding Society

2501 N.W. 7th Street
Miami, Florida 33125
See "OSHA Safety and Health Standards, 29 CFR 1910",

available from U.S. Department of Labor.
U.S. Department of Labor

Washington, D.C. 20210
NOTICE
Weld repair should be done cautiously in certain locations as
the heat can cause distortion in the case and pull components
out of alignment. Generally, the larger the crack and weld repair,
the more chance for developing distortion.
NOTICE
Best Practice: Perform Ultrasonic Testing (UT) to all weld
repairs extensive enough to require two or more weld repair
layers approximately 6.35 mm (0.250 inch) in depth.
Refer to the latest version of the American National Standards

Institute/ American Welding Society "ANSI/AWS D1.1 - Structural
Welding Code -".
Weld repairs that do not get machined should be ground flush or shaped to match the profile of the surrounding material of gear case. There should be no
visible defects present such as rollover, undercut, porosity, or slag inclusions. Ensure that each repair is inspected after the metal cools using either Liquid
Penetrant Testing (PT) or Dry Magnetic Particle Testing (MT) methods. Refer to the SEBF8148 Reuse and Salvage Guidelines , "General Salvage and
Reconditioning Techniques".
Welder Qualifications
Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from
entering the lungs of the person that is welding. Use a respirator for breathing protection.
Welders must be qualified for the appropriate type of weld that is being performed:
Shielded Metal Arc Welding (SMAW)
Flux Cored Arc Welding (FCAW)
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)/ Tungsten Inert Gas (TIG)
Welders must be qualified for the appropriate position of weld that is being performed. Refer to AWS Specifications D1.1 and D14.3 or comparable
standards for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The
welders must complete the process of certification if the welders have not used the welding processes for 6 months. The welding operator must hold a
current certification for this process. The operator must wear the appropriate equipment. The operator must also install all appropriate equipment. All
equipment must maintain the amount of fumes, heat, and ultraviolet radiation at a safe limit.
References:
Reuse & Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide"
ANSI/ AWS D1.1, D14.3
Caterpillar Manufacturing Practice MC1000-105
1/30/24, 3:42 PM SIS 2.0
Welding Preparation
Personal injury can result from flame cutting or welding on

painted areas.
The effect of gasses from burned paint is a hazard to the person

doing the cutting or welding.
Do not flame cut or weld on painted areas.
Note: Cover all exposed machined surfaces before beginning defect removal.
Defect Removal Techniques

Once a defect has been detected the defect shall be removed by grinding, air carbon/ plasma arc gouging, or machining. Cavities which have been
gouged shall be chipped or ground to remove the gouging slag. Grind smooth all uneven areas caused by gouging which present pockets to trap slag.
Non-Destructive Testing (NDT) shall be used to ensure that cracks have been removed, refer to the , SEBF8148.
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 120.
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 121.
Refer to , SEHS9031 Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Example of protection for a component that is stored for a shorter term

Example of protection for a component that is stored for a longer period
PIP-10464666
2024/01/30
12:42:05+03:00
i03753169
© 2024 Caterpillar Inc.
1/30/24, 3:42 PM
12: /01/3 666 SIS 2.0
Caterpillar:
Confidential Yellow
S 42 0

Reuse and Salvage of Water Pumps

Uploaded by

Copyright:

Available Formats

Reuse and Salvage of Water Pumps

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Reuse and Salvage of Water Pumps

Uploaded by

Copyright:

Available Formats

1/30/24, 3:42 PM SIS 2.

Reuse and Salvage of Water Pumps {1361} (SEBF8418-32)

SMCS - 1361 i09950578

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Your safety is Involved.

Media Number Publication Type & Title

Service Advisories, Service Letters, and Technical Service Bulletins

Tooling and Equipment

Required Tooling and Equipment

Part Number Description Designation

— (1) Personal Protective Equipment (PPE) Personal Protection

1P-0510 Driver Group Installation/Removal

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

Personal injury can result without following proper procedure.

During cleaning, do not damage machined surfaces.

Use appropriate thread taps to chase all threaded holes.

Take measurements at locations (A1), (A2), and (A3).

Then take measurements at locations (A4), (A5), and (A6).

Shaft and Journal Diameters

Take measurements at locations (C1), (C2), and (C3).

Then take measurements at locations (C4), (C5), and (C6).

When replacement parts are required for this product Caterpillar

Failure to heed this warning can lead to premature failures,

Nomenclature for C-9 and C9 Engines

Nomenclature for C9.3 Engines

Nomenclature for C13 Engines

Nomenclature for C15 Engines

Nomenclature for 3044,

Con illa aterpi

Nomenclature for 3176 Engines

Nomenclature for 3208 Engines

Nomenclature for 3500 Engines

Press on impeller vs bolt on impeller

Ceramic seal vs steel seal

Pinned seal retainer

Straight shaft vs tapered

Older Style Water Pumps

Current Water Pumps

Nomenclature for 3600 Engines

Later Water Pumps

Water Pump Applications for 3600 Engines

Do NOT handle the water pump by the shaft.

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

Housing and Steel Parts

Inspection and Salvage Procedures

Housing for C9 and C9.3 Engines

Housing for C13 Engines

Bearing and Seal Bore Specifications for C13

Housing for C15 Engines

Bearing and Seal Bore Specifications for C15

Housing for 3044, 3046, and 3064 Engines

Bore Size (D) Bore Size (E)

Housing for 3176 Engines

Seal Diameters for Housing on 3176 Engines