INSULATION 2558529 - Caterpillar

The results of the oil sample are the mostaccurate method of determining whether or not the idler gear bearing hasworn, or will wear prematurely. Copper level in early oil samples may beartificially elevated due to engine break in. Keep in mind the other factorsused to determine an idler gear bearing problem:
Hard starting
Engine miss or stutter
OWNER NOTIFICATION
U.S. and Canadian owners will NOT receive an OwnerNotification.SERVICE CLAIM ALLOWANCES
***** Parts Stock *****Submit one claim for all 232-3668 parts removedfrom parts stock.***** Affected Product *****
Product smu/ Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0 ? 3000
0 ? 36 mo. 100% 1.0* 0 0 0 0
0 ? 3000
0 ? 36 mo. 100% 4.5** 0 0 0 0
* The 1.0 hour of labor is for administrativeduties involved in mailing out the sample bottle, and processing the returnedsample. **Up to 4.5 labor hours will be allowedto replace the idler gear assembly and associated parts if, and only if,the oil sample result shows excessive copper.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (1- Rework Procedure)Rework Procedure
Note: This procedure is for engines fittedwith DP-210 Fuel Injection Pumps. This process can be also be used on enginesfitted with the Bosch EVPE Mechanical FIP, however one needs to put a spanneron the FIP shaft nut to hold it against the springs in the FIP. It canalso be used with a LHS PTO fitted without needing the removal of the PTO.
Preparatory Strip-down
Remove alternator adjusting link and belts iffitted.
Removewater pump and joint, not removing the 2 bottom-left screws which retainthe water pump the cover, as shown:
Remove timing case cover
Remove injector cover to gain access to glow plugs
Remove glow plugs to enable the engine to be turned
Turnthe engine in direction of rotation to enable the crankshaft and camshaftlocating pins to be fitted. Insert 230-6283 Crankshaft timing pin throughthe housing (front) and into the web of the crankshaft. Insert the 230-6284Camshaft timing pin through the camshaft gear and into the housing (front).
Idler Gear Removal
Remove the three idler fixing screws (6) and thethrust plate (7).
Note the single mark on the FIP gear may not bealigned with the two marks on the idler gear. The idler gear marks ?walk?and several more rotations would be required to align the marks. This doesnot matter.
DO NOT remove the FIP gear and do notlock the FIP.
Remove the camshaft timing pin, leave the crankshaftlocating pin in place. Remove the Camshaft gear fixing bolt (1) and removethe camshaft gear (2). Dependant on the ?fit? this may need a puller.
Nowwithdraw the idler hub and gear. Note: To remove the idler hub and gearinsert three M10 screws back in the idler hub after removal of the plate,but make no attempt to screw the fixing into the thread. Now grab the threefixings and squeeze so that they lock into the hub, then move them aboutand pull to disengage the spigot from the cylinder block. Angle the huband gear so that you can draw it out. Remember that because of the helixand the locked crank gear any other gear must be free to rotate as