IPDPB-002

IPD Products for Caterpillar 3500 SERIES ENGINES

The Standard for Quality, Innovation, Service and Support Since 1955

IPD, A SAFE AND SECURE INVESTMENT

Since 1955, IPD has lowered Caterpillar engine owner costs without sacrificing quality, engine life or performance, by providing a cost effective quality product line alternative. Our robust product line covers a wide range of products for the 3114 up to 3524 series diesel and gas engines. IPD recognizes the importance of repairing engines with quality products, as these pieces of equipment or machines are an investment and source of revenue for owners, and IPD does not take that lightly. IPD uses only quality materials, and with over 55 plus years of manufacturing experience, we have in place an excellent and extensive QC process to ensure our products pass IPDs high quality assurance standards before being shipped to customers. Additionally, our comprehensive and clearly stated warranties give our customers peace of mind when purchasing IPD products, because they know they are covered and protected. IPD is ISO9001:2008 certified by Lloyds Register, who is recognized and respected worldwide for high standards of technical competence, impartiality and independence. Being ISO9001:2008 certified provides our customers the assurance of a consistent experience with our compliance to ISO controls and processes. The extent to which IPD has developed its ISO process, and made it a part of virtually every aspect of IPD, is an uncommon practice in most companies in the aftermarket parts industry. You can read more about IPD quality and our differentiations at www.ipdparts.com. Thank you for taking the time to view this document, and we appreciate the opportunity to prove to you what truly sets IPD apart from our competition.
IPD COMPANY OVERVIEW

IPD 3500 SERIES PRODUCT LINE

IPD has been producing high quality products for 3500 series engines since the early 1990s. IPD offers a complete range of products, including gallery-cooled pistons for diesel and natural gas applications, induction-hardened cylinder liners, heavy-duty copper alloy engine bearings, and quality valve train components. Our robust product line makes IPD a leader in providing the most complete range of products available in the aftermarket for these popular engines. Additionally, IPD carries a variety of miscellaneous internal bushings for rocker arms, accessory drive and oil pump bushings, and other parts and components as outlined below. We also are aware of the many changes in specifications and metallurgies that are required between natural gas and other fuels, such as landfill and waste gas applications. Changes in valve and valve seat materials are critical to maintaining the risk free alternative that IPD can offer. At IPD, we only utilize the latest in materials and designs. IPD is in the process of expanding the availabilty of 3500 series engine parts, please check with IPD for any updates.

Items available from IPD for 3500 series engines vary between applications and serial ranges but will generally include products such as: Pistons (aluminum and IPDSteel one piece designs) Cylinder Kits (induction heat-treated liners, application-specific rings and ring sets, pins, retainers, liner o-rings) Engine Bearings (connecting rod, main, cam) Turbo Cartridges Valve Train (int/exh valves, seat inserts, guides, springs, bridges, locks, rotocoils) Gasket Sets (OEM style and IPD Style 1-2-3 complete gasket sets) Pumps (oil and water pumps, related components) Misc. Hardware

TESTED AND PROVEN

IPD is known industry-wide for our quality parts and excellent service. Our goal is to create consistent and positive interactions with our distributors and their customers from start to finish as well as offering reliable support after the sale. This starts by manufacturing IPD brand parts from high quality materials, ensuring that each part has the correct specification and tolerances and has gone through a rigorous quality control process. Our attention to detail and quality truly makes IPD stand out from our competition. Listed below are just a few examples of how IPD ensures quality control and takes the necessary steps to produce top of the line product.

HOW OUR QC PROCESS WORKS

We produce our products from concept to execution. Our process begins with a drawing which ensures the verification of exact specifications and tolerances. As shown in a sample drawing of an inspection of a natural gas application piston.

Quality control of all IPD aluminum diesel and natural gas pistons includes ultrasonic bond checks and critical dimension checks through the use of CMM and hand measuring equipment. IPD QUALITY

Cylinder liner dimensional control includes dozens of critical specifications, including inside and outside dimensions, flange specifications and oring groove size checks, which is accomplished through tools such as a CMM, height gauge, hardness tester and surface analyzer.

Valve guides, seats and springs are all critical items in heavy duty engines that require extra care. Our valve inspection program includes checking vital measurements such as valve angles, not to mention the critical metallurgies used today.

Shown here is our in-house tangential piston ring tension tester.

FROM CONCEPT, DESIGN TO MANUFACTURING

IPDSTEELTM
Piston technology has evolved significantly over the years in order to keep up with increased cylinder pressures, performance and emissions requirements. IPD has kept in sync with these evolutions as seen in our piston designs (from our earlier aluminum pistons, to our articulated two-piece designs, to our latest technology IPDSteel one piece steel pistons). In both natural gas and diesel applications, specifications (materials, tolerances, etc.) and designs are increasingly critical for proper engine life and performance. Since 2003, IPD has manufactured steel pistons in various versions, and provided product for thousands of engines in many vocations, applications, and markets worldwide. IPD began in the late 1990s working with world-class casting experts, as well as independent metallurgy specialists, to continue to evolve our IPDSteel technology and apply it to the one piece steel applications. After the concept and designs were reviewed by a variety of casting experts, including independent metallurgical evaluations, IPD subcontracted an independent company specialized in testing cylinder power components, as well as utilized extensive field testing...both with exceptional results, resulting in the IPDSteel patent pending technology that is available today.

IPD QUALITY

How it works: Utilizing modern casting processes when controlled properly along with the correct metallurgy and heat treating, offers increased performance over previous designs and methods. Our patent pending process begins with a base metallurgy which includes a 4130 high strength alloy steel to control the carbon content of the material. This steel when heated properly has high strength qualities and controls brittleness assuring our rigid quality standards are adhered to. Our patent pending process continues with a high quality investment casting using the lost wax process. The process is tightly controlled throughout to assure a high integrity casting. X-ray diagnosis was utilized in the development process to assure casting integrity and ongoing sampling of castings assures our rigid quality standards are adhered to.

FEATURED PRODUCTS
Our product line for the 3500 series diesel and gas engines have many unique attributes that truly distinguishes us from our competition. Our patent pending one piece steel piston, valve train and gasket sets program play an important role in our product offering, and showcase IPDs commitment to innovation and quality. The following section will discuss in further detail some of the distinct IPD product customization, value and quality.

IPD...INNOVATION, NOT IMITATION

IPD is proud to feature our one piece steel piston, which utilizes our IPDSteelpatent pending technology for our 3500 series product line. Each piston is manufactured from the high strength alloy and heat treated steel casting process which has been extensively tested and successfully proven in the 3500 series applications. These one piece steel pistons also showcase another way that IPD truly sets the bar for innovation. In comparison to most aftermarket companies, who solely reengineer products from the originating company, IPD stands apart. In partnering with our customers worldwide, IPD has enhanced upon the original design in efforts to create a better product.

Oil Gallery Retention Plate

The IPDSteel one piece piston features new design enhancements made possible by IPDs patent pending one piece oil gallery retention plate. In order to prevent the piston from experiencing extreme thermal loading as seen in other products in the market place, this innovative one piece design limits plate movement and secures the oil gallery retention plate firmly in place as seen in example below.

IPD ONE PIECE DAM PLATE

TRADITIONAL TWO PIECE DAM PLATE

FEATURED PRODUCTS
VALVE TRAIN
At IPD, our valve train products offer customers a safe and cost effective alternative. Our valve train product is developed from materials specifically designed for diesel and natural gas applications and not from automotive grade materials, a common aftermarket industry practice. IPD puts quality above our cost savings which gives our customers the assurance that they arent exposing their equipment to risk that could potentially decrease cylinder head life expectancy. Our valve guides maintain uniformed dimensions, knurling and tight tolerances to achieve maximum valve cooling and oil control, as well as valve springs made from the highest quality steel, correct tensions and shot-peened for strength and long service life.

IPD GASKET MATERIALS AND TECHNOLOGY

FEATURED PRODUCTS

The quality of our materials at IPD defines our gasket program. Many aftermarket gasket manufacturers compromised the quality of their gaskets by using materials not intended to work under the extreme conditions that most diesel and natural gas engines are subject to. These lighter duty materials will lead to reduced sealing capability or in more extreme cases, lower engine performance and engine life. IPD use the latest materials, verifying through our rigorous QC process that each part number receives the correct material specification for the application. Critical tests and measurements are applied to all of our gasket materials to assure that there are not performance issues within our program. Some of these include: Creep Relaxation This indicates the ability of the material to retain its original bolt torque specification after exposure to stress. Crush Resistance Density Crushing or extrusion can occur when compressive forces exceed the point where the gasket materials pore volume is zero, resulting in leakage. Tensile Strength This is a measurement of the materials resistance to blow out when used in high pressure or high torque applications.

FEATURED PRODUCTS
IPD GASKET PROGRAM
We realize that demands can differ between markets or applications so we offer two distinct gasket systems:

Modular Original Style Multiple Sets

These sets are based on the same multiple groups that you might be accustomed to from the OEM. They are specific to an engine arrangement or a close grouping of arrangements and serial numbers. Many times when ordering the Modular Original Style Multiple Sets, you must order multiple part numbers (possibly up to 8 or 9 or more sets) to rebuild your engine as they can lack the items that are commonly replaced or needed to reinstall a component. IPD offers a unique and custom gasket set to alleviate these issues.

IPDStyle 123 Consolidated Sets

FEATURED PRODUCTS

For years, IPD customers complained of difficulty ordering, shipping and maintaining inventory of OE style multiple sets. In the late 1980s, IPD developed and customized IPDStyle 1-2-3 gasket sets to: Reduce IPD distributors and rebuilders inventory by consolidating a wider range of serial and arrangements than was possible with the Original Style Multiple Sets. Reduce the time to order and stock many different multiple style sets in order to cover a wider range of equipment and engines. Packaging IPDStyle 1-2-3 with individual groupings based on the engine component or the location of the gaskets in the engines in easy to identify bags. Marking all gaskets and orings clearly with the part numbers for easy identification, reducing engine technicians time to find the proper part. IPDStyle 1-2-3TM sets are designed from the ground up with the help from our customers who rebuild these engines. Do not confuse these with other companies that simply put all the multiple sets into one box and call it consolidated, for they may still lacking critical items or duplicating pieces.

QUICK REFERENCE GUIDE FOR IPD 3500 SERIES PRODUCTS

DESCRIPTION
CYLINDER COMPONENTS Cylinder Kit-IPDSteel Cylinder Kit-IPDSteel PLG2995204 PLG3145005 Diesel Diesel Diesel Diesel Diesel Diesel Gas Gas Includes IPDSteelTM piston, Heat Treated Liner, Rings, Pin, Retainers & Liner seals Includes IPDSteelTM piston, Heat Treated Liner, Rings, Pin, Retainers & Liner seals Includes Piston, Liner, Rings, Pin, Retainers & Liner Seals, Induction Heat Treated Liner Includes Piston, Liner, Rings, Pin, Retainers & Liner Seals, Induction Heat Treated Liner Includes Piston, Liner, Rings, Pin, Retainers & Liner Seals, Induction Heat Treated Liner Includes Piston, Liner, Rings, Pin, Retainers & Liner Seals, Induction Heat Treated Liner Includes Piston, Liner, Rings, Pin, Retainers & Liner Seals, Induction Heat Treated Liner Dual Ni-Ring Insert - Includes Piston, Liner, Rings, Pin, Retainers & Liner Seals, Induction Heat Treated Liner Single Ni-Ring insert- Available mid 2010, For select engine operating at or above 1500 RPM Available in PLG Cylinder Kits only Available in PLG Cylinder Kits only QUICK REFERENCE GUIDE

IPD PART NUMBER

DIESEL OR GAS

NOTES

Cylinder Kit-13.0:1 Compression PLG7C2431 Ratio Cylinder Kit-13.5:1 Compression PLG9Y2100HD Ratio Cylinder Kit-13.0:1 Comp. Ratio/ PLG9Y4124HD Thick Flange Liner Cylinder Kit- 13.0:1 Comp. Ratio/Narrow Flange Liner Cylinder Kit-8.0:1 Compression Ratio PLG9Y4124HD/ NF PLG1014140

Cylinder Kit-11.0:1 Compression PLG6I4609 Ratio Cylinder Kit-11.0:1 Compression PLG1973765 Ratio Piston - IPDSteel ONE Piece Steel Piston Piston - IPDSteel ONE Piece Steel Piston Piston 13.0:1 Compression Ratio Piston 13.5:1 Compression Ratio Piston 13.0:1 Compression Ratio Piston 8.0:1 Compression Ratio Piston 11.0:1 Compression Ratio Piston 11.0:1 Compression Ratio Liner, Cyl. 6.69 Bore Liner, Cyl. 6.69 Bore Ring Set Ring Set Ring Set Piston Pin Piston Pin Piston Pin Retainer Piston Pin Retainer Liner Seal Set 2995204 3145005 7C2431 9Y2100HD 9Y4124HD 1014140 6I4609 1973765 1106993 1238206 RS3500D 7E2899 3500RS1 1388506 2638955 8N7296 2531238 6V3774

Gas

Diesel Diesel Diesel Diesel Diesel Gas Gas Gas Diesel/Gas Diesel/Gas Diesel Gas Diesel Diesel/Gas Diesel Diesel/Gas Diesel Diesel/Gas

Available mid 2010 Thick Flange, Induction Heat Treated Narrow Flange, Induction Heat Treated

( 1 pc. Steel pistons only ) ( 1 pc. Steel pistons only ) Includes 3 liner seals and 1 band seal

QUICK REFERENCE GUIDE FOR IPD 3500 SERIES PRODUCTS

DESCRIPTION
Lifter Lifter, Repair Kit Bridge, Valve Bridge, Valve Button, Rocker Arm Ring, Rocker Arm Screw, Rocker Arm Adjusting Bushing, Rocker Arm Bushing, Rocker Arm Valve, Intake and Exhaust Valve, Exhaust Valve, Exhaust Valve, Exhaust Valve, Intake and Exhaust Guide, Valve QUICK REFERENCE GUIDE Guide, Valve Guide, Valve Guide, Valve Guide, Valve Guide, Valve Guide, Valve Guide, Valve Guide, Valve Guide, Valve Guide, Valve Spring, Valve Spring, Valve Lock, Valve Lock, Valve Rotocoil Rotocoil Rotocoil Insert, Valve Seat Insert, Valve Seat Insert, Valve Seat Insert, Valve Seat

IPD PART NUMBER

2636679 2636679RK 2657538 2657537 8F8858 9F7707 2002003 1W4594 2302620 7E4609 1219839 1219835 1944897 1047184 1339306 9Y1847 1976995 1491982 1665944 2763875 2763876 9Y1846 9Y1847 1845494 1845495 1011177 1011180 2A4429 1977055 1976999 1977062 1977063 1302607 1302608 6I1713 1225963

DIESEL OR GAS
Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel Diesel Diesel Diesel Diesel Diesel/Gas Diesel Diesel/Gas Diesel Diesel Diesel Diesel Diesel Gas Gas Gas Gas Diesel Diesel Diesel/Gas Diesel Diesel/Gas Diesel/Gas Diesel/Gas Diesel Diesel Gas Gas Late style Lifter Assembly

NOTES

VALVE TRAIN & CYLINDER HEAD COMPONENTS Lifter Repair Kit, Includes Pin and Roller Exhaust Intake

30, Intake and Exhaust in early engines 30 Exhaust valve w/tapered stem-Later engines 45 Exhaust valve 1/2 valve stem. Updated from the 1219835 20 valve with Chrome Stem for use as Intake and Exhaust 3/8 Intake and Exhaust/Non-counter bored 3/8" Intake/Counter bored for extra oiling 1/2 Exhaust- used with 1944897 valve 3/8, .005 Oversized 3/8, .020 Oversized Exhaust, .127 mm O.S./O.D. Exhaust (non landfill) Intake (non landfill) Exhaust (non landfill) Intake (landfill) Inner Outer Intake/Exhaust ( 3/8 valves ) Exhaust ( 1/2 exhaust valve only ) Intake/Exhaust-without shield Intake Exhaust 20 Intake 45 Exhaust 20 Intake/Exhaust with 2.367 O.D. and .460 Depth 20 Intake with swirl plate

QUICK REFERENCE GUIDE FOR IPD 3500 SERIES PRODUCTS

DESCRIPTION
BEARINGS Connecting Rod Bearing Connecting Rod Bearing Main Bearing Main Bearing Thrust Plate Cam Bearing Cam Bearing Cam Bearing Bushing, Connecting Rod 1077330 1077331 1496031 1496032 7C6209 7N2048 1161359 1011198 1181655 Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Diesel/Gas Early Style Late B Block with an A cam Late B Block with a B cam Standard 0.025 Standard 0.025

IPD PART NUMBER

DIESEL OR GAS

NOTES

COOLING AND LUBRICATION SYSTEM Cooler Core, Oil NEW Water Pump Water Pump Rebuild Kit 1245142 2128177 2225152 Diesel/Gas Diesel/Gas Diesel/Gas 3512 & 3516 select applications Kit includes shaft and impeller. Covers 2128172, 2128177, 0R9673, 0R9671, 10R1671 and 10R1669 pumps Kit includes shaft and impeller. Covers 1664380, 1664377, 2128175, 2128176, 0R9670, 0R9672, 10R1668 and 10R1670 pumps Kit includes shaft and impeller. Covers 6I3520, 7E9781, 7E9782, 2128168, 2128169, 2128166, 0R3192 and 0R4570 pumps 170 F 190 F ( OLD # 7C3095 )

Water Pump Rebuild Kit

2225153

Diesel/Gas

QUICK REFERENCE GUIDE

Water Pump Rebuild Kit

2219278

Diesel/Gas

Regulator Regulator

6I4954 2477133

Diesel/Gas Gas

MISCELLANEOUS ITEMS AVAILABLE FROM IPD Steel Spacer Plate NEW Cartridge, Turbo NEW Cartridge, Turbo IPDStyle 123TM Gasket Sets 2603904 1182988 7W3570 Diesel/Gas Diesel/Gas Diesel/Gas Can replace aluminum spacer plates

This exclusive, IPD Innovation offers the engine rebuilder a variety of engine gasket kits specifically designed to perform a function such as head replacement, in-frame or out of frame overhauls by providing the required gaskets and seals to perform the job IPD offers a full range of the OE style multiple groups such as upper, lower, front, rear etc.

OE Style Multiple Gasket Groups

IPD ENGINE MODEL SUMMARY

CATERPILLAR
D3508 / D3512 / D3516 / D3524 G3508 / G3512 / G3516/ G3520 D3406 / D3408 / D3412 D3406E / D3408E/ D3412E G3406 / G3408 / G3412 D3304 / D3306 / D333 G3304 / G3306 / G333 3204 / 3208 3114 / 3116 / 3126 3064 / 3066 D379 / D398 / D399 G379 / G398 / G399 D353 / G353 D339 / D342 / G342 D343 / D346 / D348 C7, C9, C10/3176C, C12/3196 C15 / C15 Acert

DETROIT DIESEL
60 Series

ISX15 / QSX15

CUMMINS

WAUKESHA
7042/7044

IPD brand quality products distributed by:

IPD

23231 Normandie Ave. Torrance, California 90501 USA T. +1 (310) 530-1900 F. +1 (310) 530-2708 Sales: +1 (310) 602-5399 Email- sales@ipdparts.com

Website- www.ipdparts.com

All manufacturers names, numbers, symbols and descriptions are for reference only. It is not implied that any part is the product of the manufacturer. Caterpillar, Cat, Detroit Diesel, Cummins, and Waukesha are registered trademarks of their respective owners. Copyright 2013 IPD 3/13 IPDPB-002