Reuse and Salvage for C4.4, C6.6 & C7.1 Engine Cylinder Blocks {0374, 0599, 0701, 0705, 1200, 1201} Caterpillar

Caterpillar Products

All C4.4 Engines

All C6.6 Engines

All C7.1 Engines

Introduction

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage 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 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).

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 NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

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. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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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. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

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, you must 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 gives specifications and repair procedures for new and used cylinder blocks used with C4.4, C6.6 & C7.1 Engines. A cylinder block that meets the specifications in this guideline can be expected to give normal performance. This normal performance will last until the next overhaul.

Never install a part that does not meet the specifications in this guideline. During reconditioning, correct any conditions that might have caused the original failure.

Service Letters and Technical Information Bulletins

References

Tooling and Equipment

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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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.

Measurement Requirements

Initial Cleaning of the Engine

Illustration 3	g06238164

Cap all machined surfaces and plug all the hoses and fuel lines.

Clean all the external surfaces before the engine is disassembled. Clean all the external surfaces before the engine is brought into the shop. Use a high-pressure washer to spray the engine with hot water and soap or 174-6858 Cleaner.

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

After the initial cleaning of the engine, disassemble the engine. Refer to the appropriate Disassembly and Assembly manual for your engine.

All fasteners should be compared against Reuse and Salvage Guidelines, SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines". Pay special attention to head bolts, main bolts, connecting rod bolts, and rocker shaft bolts when considering reusability. Any visual damage to the bolts should disqualify the bolt from reuse.

Note: Itis recommended to replaceall cylinder head bolts and the spacer plates (if applicable) on any engine that has experienced a failure of the top deck/cylinder head joint.

Cleaning the Cylinder Block

One of the major reasons for a bearing failure after an engine overhaul is damage caused by debris in the oil passages. Remove all dirt, debris, and metal shavings from all openings, ports, and passages. Refer to M0080689Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure" for cylinder block cleaning.

C4.4, C6.6 & C7.1 Cylinder Block General Information

Illustration 4	g06305041
Bottom view of C4.4 Cylinder Block

Locations of the center of the cylinder bores are measured from the center of the dowel location on the mounting surface for the oil pan.

(A) 420.27 ± 0.2 mm (16.546 ± 0.008 inch)

(B) 302.795 ± 0.2 mm (11.921 ± 0.008 inch)

(C) 178.97 ± 0.2 mm (7.046 ± 0.008 inch)

(D) 61.495 ± 0.2 mm (2.421 ± 0.008 inch)

Measure cylinder bore center location from the center of the dowel location on the mounting surface for the oil pan for C4.4 Tier 4i and Tier 4F 326-7452, 342-4763, 351-8229, 351-8234, 351-8238, 351-8243, 352-9748, 358-2937, and 358-2980 Cylinder Blocks

(A) 421.12 ± 0.2 mm (16.580 ± 0.008 inch)

(B) 301.12 ± 0.2 mm (11.855 ± 0.008 inch)

(C) 181.12 ± 0.2 mm (7.131 ± 0.008 inch)

(D) 61.12 ± 0.2 mm (2.406 ± 0.008 inch)

Illustration 5	g06305045
Typical view of Cylinder Block

Cylinders can be bored 0.5 mm (0.02 inch) oversized for C4.4, C6.6, and C7.1 and 1.0 mm (0.040 in) for C7.1. The cylinder bore diameter of the stock head gasket is still acceptable to be used with the 0.5 mm (0.02 inch) oversized bore diameter. The standard head gasket can still be used as long as the top deck height is still within the NEW specifications listed in Table 4.

Note: Refer to "Surface Texture of Cylinder Bores" for information on surface texture of the cylinder bores and more information on the specific oversize boring procedures.

Note: The Permissible Wave Depth in Table 5 should be added to top deck surface texture.

If the top deck surface of the cylinder block must be milled, the top deck must be milled prior to boring the cylinders. The top deck height is measured from the centerline of the main bearing bore to the top deck surface of the engine block. When removing 0.25 mm (0.010 inch) or 0.50 mm (0.020 inch) from the top deck surface, a new thicker head gasket must be used.

The following table lists the part numbers of the head gaskets that are to be used as well as the oversized pistons.

To use the standard head gasket, the piston projection above the top surface of the cylinder block should be 0.21 mm (0.008 inch) to 0.35 mm (0.014 inch).

When removing 0.25 mm (0.010 inch) from the top deck surface, the piston projection should 0.46 mm (0.018 inch) to 0.61 mm (0.024 inch). The thicker head gasket must then be used.

The projection of the piston must be measured after any of the following components are replaced or if the top deck surface is machined.

• Crankshaft

• Cylinder head

• Connecting rod

• Bearing for the piston pin

Refer to "Measuring Piston Projection" in this document for the correct procedure.

Note: The top of the piston should NEVER be machined to obtain the correct projection of the piston.

Cleaning the Cylinder Block

The following table lists the maximum permitted contaminant levels for the finished machined cylinder block.

Measuring Piston Projection

When reusing the original piston, the original connecting rod should also be used in the original cylinder where the piston and rod assembly was removed.

If piston projection is not within the allowed range, a different length of connecting rod may be used to achieve the correct projection. Different lengths of connecting rods are available to help maintain the correct projection of the piston. The length of the connecting rod is determined by offset machining the inner bore of the piston pin bearing. The offset will move the position of the piston, making the overall length of the connecting rod shorter or longer. The projection of the piston will determine what length of connecting rod should be used.

The other option of correcting piston projection is to purchase a new piston pin bushing. The new bushing can have the center of the inside finished diameter offset machined to change the projection of the piston.

Illustration 6	g06305063

Use the following procedure to measure the projection of the piston. Use the top surface of the cylinder block to zero Tooling (H).

1. Rotate the crankcase until the piston is just before top dead center.

2. Position Tooling (H) and Tooling (I) and slowly rotate the crankshaft to determine when the piston is at the highest position. Record this dimension and determine if the piston projection is within specifications.

Cylinder Bore Chamfers and Centerline

The top of all cylinder bores must be chamfered. Refer to the following illustration and table for the correct dimensions.

Illustration 7	g06305067

Illustration 8	g06305126

All centerlines are measured from Datum line (D). Datum line (D) is the vertical plane from the crank web thrust face.

Surface Texture of Cylinder Bores

The surface texture of the cylinder bores must meet the following requirements. Failure to meet the surface texture may result in the engine not meeting the required emissions legislation. When an oversize piston kit is installed, all the pistons must be oversized and installed as a complete set. Using only one or two oversize piston kits may result in an engine imbalance. If one piston bore needs to be machined oversize, all the remaining piston bores must also be machined oversize. The oversizing of the piston bore is a four-step process. The angle of the crosshatch is required to be 30°-35° off the horizontal axis of the bore.

• Rpk, Rk, Mr1, and Mr2 are defined by BS EN ISO 13565-2:1998

• Rz value may be expected to be less than 5 microns

• Rz as defined by BS EN ISO 4287:2000

• The honing finish crosshatch is required with a horizontal (tangential to axis of the cylinder bore) inclusive circumferential angle of 30 degrees to 35 degrees when measured midway along the bore.

• The surface texture shall be cleanly cut and free from excessive tearing, folding, smearing, and foiling. Surface to be uniformly cut in both directions throughout the length of the cylinder bore.

Camshaft Bushing

Illustration 9	g06305135

When replacing the camshaft bushing, the bushing should not protrude past the face of the engine block. The bushing should be installed to a maximum depth (S) of 0.2 mm (0.008 inch) for C4.4, C6.6 & Tier 2 and 3 only C7.1) . The oil hole (T) in the bushing should be aligned with the oil supply hole in the engine block. The bushing should be installed dry without the use of any lubricant. Be sure not to damage the block during the removal of the old bushing.

Thermal Spray Procedures for Top Surface Deck

Spraying Under Top Supported Liner

Listed below are the arc and flame spray procedures for providing a sufficient thermal spray coating on top decks. Based on complexity and process variables, arc spray is the preferred technology for this process.

Arc spray is the only validated and approved process for spraying under top supported liner flanges. Flame spray should only be used for deck height recovery with the use of inserts under the liner flanges.

Arc Spray Equipment and Procedure

Flame Spray Equipment and Procedure

Thermal Spray Procedures for Crankshaft Main Bearing Saddle Area

Illustration 10	g06370992

Part Description

Arc Spray Equipment and Procedure

Flame Spray Equipment and Procedure

Storage Procedures

Proper protection of the cylinder block from corrosion is important. Corrosion will start in as little as one hour after the cylinder block has been cleaned.

When the cylinder block will not be inspected for one hour or less the cylinder block should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The cylinder block should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 11.

When the cylinder block will not be inspected in two days or more the cylinder block 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 cylinder block. See Illustration 12.

Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Illustration 11	g06278538
Example of protection for a component that is stored for a shorter term

Illustration 12	g06278539
Example of protection for a component that is stored for a longer period