- Caterpillar Products
- All Cat Engines
Introduction
Revision | Summary of Changes in SEHS8919 |
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20 | Added new serial number prefixes |
19 | Combined guideline SEBF8793, added crack detection methods, and repaired 36 pixelated illustrations. |
18 | Added new serial number prefixes |
17 | Added new serial number prefixes, confidential yellow note. |
© 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.
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 provides guidelines for reusing cast iron cylinder blocks for all Caterpillar engines.
This guideline gives the materials and the welding procedures that are needed for the salvage of a cast iron engine cylinder block. Do not make the repair if the area is critical to the structure of the block. This guideline provides information that is necessary to repair a crack. This guideline also provides information that is necessary for the repair of a missing section. The failure of a connecting rod is a likely cause of a missing section. This procedure may also be used to replace a porous section of a block.
Service Letters and Technical Information Bulletins
NOTICE |
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The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired. |
References
References | |
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Media Number | Title |
SEBF8882 | Reuse and Salvage Guideline, "Using LOCK-N-STITCH® Procedures for Casting Repair" |
Tooling and Equipment
NOTICE |
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Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Required Tooling and Equipment | ||
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Part Number | Description | Quantity |
Ball Peen Hammer | 1 | |
Repair Kit | 1 | |
Repair Kit | 1 | |
Curved Handle Wire Brush | 1 | |
Penetrant | As needed | |
Grinding Disc | As needed | |
Grinding Disc | As needed | |
Thread Lock Compound | 1 | |
Inspection Mirror | 1 | |
Thread Lock Compound | 1 | |
Wheel Grinder Group | As needed | |
Respirator | 1 | |
Crack Detection Kit | 1 | |
Lint Free Shop Towels | 1 | |
UV Lamp Group | As needed | |
- | Oxy-Propane Kit | 1 |
- | Lifting Eye Assemblies | As needed |
- | Carbon Arc Gouging Torch | As needed |
- | Suitable Lifting Device | As needed |
Safety
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. |
Do not operate or work on this product unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
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. 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 Society2501 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 LaborWashington, D.C. 20210 |
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. |
Recommended Welding Electrodes
Use a UTP-8 welding electrode for cast iron welding. The polarity of the electrode is DC Straight. This electrode leaves a machinable weld deposit.
Use a UTP-81 welding electrode for joints on low-quality castings. The polarity of the electrode is DC Reverse. This electrode leaves a machinable weld deposit.
Use a UTP-85FN welding electrode for castings that are contaminated. Use a UTP-85FN welding electrode when UTP-8 or UTP-81 cause a weld to spall. The polarity of the electrode is DC Reverse. This electrode leaves a machinable weld deposit.
Use a UTP-86FN welding electrode for welds that require a
This table includes the electrodes that are recommended for the welding procedures in this instruction.
Recommended UTP Welding Electrodes | ||||
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UTP Part Number | Electrode Diameter | Polarity | Amperage | Welding Speed (1) |
UTP-8 | |
DC Straight | 45 | |
UTP-8 | |
DC Straight | 60-80 | |
UTP-8 | |
DC Straight | 90-110 | |
UTP-81 | |
DC Reverse | 60-80 | |
UTP-81 | |
DC Reverse | 90-110 | |
UTP-85FN | |
DC Reverse | 60-80 | |
UTP-86FN | |
DC Straight | 60-80 | |
UTP-86FN | |
DC Straight | 90-110 | |
(1) | Welding speed is inch mm (inch) per minute. |
Identification of Structural Areas
Certain areas of a cylinder block are critical to the structure of the cylinder block. DO NOT weld on these surfaces. All questionable areas must be approved by Caterpillar. These illustrations show the structural areas of a cast iron cylinder block. DO NOT weld on these areas.
Illustration 3 | g06304232 |
In-Line Cylinder Block (1) Saddle for main bearing cap (2) Web for main bearing cap |
Illustration 4 | g06304235 |
Vee Block (1) Saddle for main bearing cap (2) Web for main bearing cap |
Preparation of Joint and Surface According to Type of Damage
The steps in this section will help to repair the following types of damage.
- Cracks that are the result from handling damage or extreme operating conditions
- Damaged sections that are the result from the failure of a connecting rod
- Cracks that can be welded from both sides of the cylinder block
Note: If oil or water leaks from a casting, check the block for porous iron. Remove that porous section and follow the repair procedure for a missing section. Missing sections are typically welded in line with the cylinders.
Crack
Illustration 5 | g06304238 |
Cracks that can be welded from either side
If you have a crack that can be welded from both sides, clean both surfaces. Prepare both surfaces with the air carbon arc torch. Refer to "Preparation of Joint and Surface According to Type of Damage" section for more information. Once the required preparation is completed, continue with the instructions that are in the "Blocking a Crack" section of this guideline.
Repeat the same process for the other side of the crack.
Illustration 6 | g06304240 |
Remove one-third of the base material from each side of the crack (side (A) and side (C)). One-third of the casting (B) must exist for a successful weld repair. |
Missing Section
If oil has caused pores in a cast iron section, it may be necessary for you to remove that section. After the section has been removed, install either a cast iron section or a steel section.
Illustration 7 | g06304243 |
When you install a piece of mild steel plate (3) as a replacement for a missing section of cylinder block, always blend the edges of the cylinder block (D) to provide a proper fit for the plate. |
Carbon Arc Gouging
Illustration 8 | g06304245 |
Do not remove more than two-thirds of the base material. One-third of the wall thickness (E) must exist for a successful weld repair. |
- When you need to prepare a deep crack that is in a thick section of the engine block, use an air carbon arc torch to prepare the crack.
- Remove all surface oxides that developed during the cutting process. You must remove this layer before you can make a weld pass. Use an electric grinder with a carbide round cutter to remove this surface.
- Use an electric die grinder to remove all sharp edges. All edges should be in the shape of an arc. Do not grind angles at an edge.
Cleaning
- Before the first weld pass, prepare the surface. Refer to the "Blocking a Crack" section of this guideline.
- Thoroughly clean the weld area before the first weld pass. If the proper cleaning procedure is not performed correctly, the weld may fail. Remove all oil, grease, and paint from the weld area. Also, clean the areas which may be affected by the heat from the weld.
- Make the first weld pass.
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Personal injury can result from flying debris.
Chips or other debris can fly off objects when struck.
Wear protective glasses to avoid injury to your eyes. All tools included in this topic must be hardened to Rockwell C 37-42 before use.
- Clean the weld. Wire brush or grit blast the surface to remove any slag that formed during the weld pass.
Crack Detection Methods
After the weld area has been cleaned, check for cracks. It is necessary to find small cracks before the welding process.
NOTICE |
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Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings. |
Crack detection methods or Non-Destructive Testing (NDT) are utilized for examining components for cracks without damaging the component. Visual inspection (VT), Liquid Penetrant Testing (PT), Magnetic Particle Inspection (MT), Ultrasonic Testing (UT), Radiographic Testing (RT) and Eddy-Current Testing (ET) are recommended methods. There may be more than one acceptable crack detection method for the inspection of a given part, though the liquid penetrant is the most versatile. For example, the liquid penetrant method can be used when inspecting smooth machined components such as shafts, gear teeth, and splines, but using the Wet Magnetic Particle Inspection is more accurate. Refer to Table 5 for advantages and disadvantages and Table 6 for standards and requirements for these NDT methods.
Crack Inspection Method Advantages vs. Disadvantages | ||
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Inspection Method | Advantages | Disadvantages |
Visual Surface Inspection (VT) | - Least expensive
- Detects most damaging defects - Immediate results - Minimum part preparation |
- Limited to surface-only defects
- Requires inspectors to have broad knowledge of welding and fabrication in addition to non-destructive testing |
Liquid Penetrant (PT) | - Inexpensive - Minimal training - Portable - Works on nonmagnetic material |
- Least sensitive - Detects surface cracks only - Rough or porous surfaces interfere with test |
Dry Magnetic Particle (MT) | - Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities |
- Works on magnetic material only - Less sensitive than Wet Magnetic Particle |
Wet Magnetic Particle (MT) | - More sensitive than Liquid Penetrant - Detects subsurface as much as |
- Requires Power for Light - Works on magnetic parts only - Liquid composition and agitation must be monitored |
Ultrasonic Testing (UT) | - Most sensitive - Detects deep material defects - Immediate results - Wide range of materials and thickness can be inspected |
- Most expensive - Requires operator training and certification - Surface must be accessible to probe |
Eddy-Current Testing (ET) | - Surface and near surface flaws detectable -Moderate speed/Immediate results -Sensitive to small discontinuities |
- Difficult to interpret - Only for metals -Rough surfaces interfere with test - Surface must be accessible to probe |
Radiographic Testing (RT) | -Detects surface and internal flaws - Minimum part preparation - Can inspect hidden areas |
- Not for porous materials - Radiation protection needed - Defect able to be detected is limited to 2% of thickness |
Applicable Crack Detection Standards | |||
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Inspection Method | Standard | Acceptance
Criteria |
Required
Personnel Qualifications |
Visual Surface Inspection (VT) | EN-ISO 5817
AWS D1.1 |
EN-ISO 5817 - Level B
AWS D1.1 - Table 6.1 |
EN-ISO 9712 - Level 2
ANSI-ASNT SNT-TC-1A Level 2 |
Liquid Penetrant Testing (PT) | EN-ISO 3452
ASTM E165 |
EN-ISO 23277
AWS - D1.1 |
EN-ISO 9712 - Level 2
ANSI-ASNT SNT-TC-1A Level 2 |
Magnetic Particle Testing (MT) | EN-ISO 17638
ASTM E709 |
EN-ISO 23278 - Level 1
AWS D1.1 - Table 6.1 |
EN-ISO 9712 - Level 2
ANSI-ASNT SNT-TC-1A Level 2 |
Ultrasonic Testing (UT) | EN-ISO 17640 - Level B
AWS D1.1 |
EN-ISO 11666 Technique 2 - Level 2
AWS D1.1 - Class A - Table 6.3 |
EN-ISO 9712 - Level 2
ANSI-ASNT SNT-TC-1A Level 2 |
Eddy-Current Testing (ET) | EN-ISO 15549
ASTM E426 |
EN-ISO 20807 | EN-ISO 9712 - Level 2
ANSI-ASNT SNT-TC-1A Level 2 |
Radiographic Testing (RT) | EN-ISO 5579
ASTM E94 |
EN-ISO 10657-1 | EN-ISO 9712 - Level 2
ANSI-ASNT SNT-TC-1A Level 2 |
Visual Surface Inspection (VT)
Illustration 9 | g06085008 |
Example of Visual Inspection Tools (A) Flashlight or adequate light source (B) Magnifying eye loupe (C) Tape measure or other measuring device (D) Inspection mirror (E) Weld size inspection gauges |
Components and welds that are to be inspected using PT, MT, or UT shall first be subject to Visual Surface Inspection (VT). Visual Inspection is often the most cost-effective inspection method and requires little equipment as seen in Illustration 9. It is suggested that at a minimum personnel performing Visual Inspection are either trained to a company standard or have sufficient past experience and knowledge with regard to the components being inspected. It is also suggested that personnel performing visual inspections take some type of eyesight test on a regular basis.
Liquid Penetrant Testing (PT)
Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals. |
Materials and Equipment Required
Refer to Tooling and Equipment Table 3 for part numbers.
- Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.
- Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.
- Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrant indications.
- Wire Brush: Removes dirt and paint.
- Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
- Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry. If there is visible crack remove paint using paint remover or wire brush.
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Illustration 11 g06107081 Typical example of applying penetrant. - Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.
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Illustration 12 g06107088 Typical example of removing excess penetrant oil. - The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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Illustration 13 g06107094 Typical example of applying developer. - Before using Developer, ensure that it is mixed thoroughly by shaking can. Holding can approximately
203.20 - 304.80 mm (8.00 - 12.00 inch) away from part, apply an even, thin layer of developer over the area being inspected. A few thin layers are a better application method than one thick layer.Show/hide tableIllustration 14 g06084042 Typical example of cracks found during a liquid penetrant testing. - Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 14. Clean the area of application of the developer with solvent cleaner.
Illustration 10 | g06107074 |
Typical example of pre-cleaning area. |
Dry Magnetic Particle Testing (MT)
Materials and Equipment Required
Refer to Tooling and Equipment Table 3 for part numbers.
Illustration 15 | g06085930 |
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke. (C) Dry powder bulb. |
- Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.
- Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.
- Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.
- Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least
4.5 kg (10 lbs) . - Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.
- All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.
Procedure
- Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.
- Apply the magnetic field using the yoke against the faces and inside diameter of each bore.
- Simultaneously apply the dry powder using the dry powder blower.
- Remove excess powder by lightly blowing away the dry particles.
- Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.
- Observe particles and note if any clusters of particles appear revealing an indication.
- Record the size and shape of any discontinuities or indications found.
Wet Magnetic Particle Testing (MT)
Materials and Equipment
Refer to Tooling and Equipment Table 3 for part numbers.
Illustration 16 | g06085937 |
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process. |
Illustration 17 | g06003178 |
Pear Shaped Centrifuge Tube |
- Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.
- Concentration:
- The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.
- Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a
1 mL (0.034 oz) stem with0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 17. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between0.1 mL (0.0034 oz) and0.25 mL (0.0085 oz) in a100 mL (3.40 oz) sample. - Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
- The oil shall have the following characteristics:
- Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.
- Low inherent fluorescence and be non-reactive.
- The conditioning agents used in the conditioned water shall have the following characteristics:
- Impart good wetting characteristics and good dispersion.
- Minimize foaming and be non-corrosive.
- Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at
38° C (100° F) . - Non-fluorescent, non-reactive, and odorless.
- Alkalinity shall not exceed a pH of 10.5.
- Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least
4.5 kg (10 lbs) .
Procedure
- Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.
- Apply the magnetic field using the yoke against the surface in the area to be inspected.
- For case hardened and ground surfaces:
- Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used.
- Visually inspect for indications of discontinuities using the proper illumination.
- Record the size and shape of any discontinuities found.
Ultrasonic Testing (UT)
Note: Crack depth cannot be accurately determined by UT, only full depth cracking can be consistently determined. For cracks that are not full depth, an indication of a partial depth cracks can be detected by an experienced technician.
NOTICE |
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All personnel involved in ultrasonic testing shall be qualified to Level 2 in accordance to standards stated in Table 6. |
Refer to Tooling and Equipment Table 3 for part numbers.
- Ultrasonic Testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.
- There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.
- Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect form the backsurface of the material to project the thickness of the material.
- Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.
Eddy-Current Testing (ET)
NOTICE |
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All personnel involved in Eddy-Current Testing shall be qualified to Level 2 in accordance to standards stated in Table 6. |
Illustration 18 | g06090873 |
Eddy-Current Testing |
Eddy-Current Testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow is induced in the test object. Changes in the flow caused by variations in the specimen are reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and techniques. Major applications of eddy-current testing are surface inspection and tubing inspections.
Radiographic Testing (RT)
Note: CAUTION: This process is dangerous. Only qualified personnel and test equipment should be appointed to perform this type of testing.
NOTICE |
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All personnel involved in radiographic testing shall be qualified to Level 2 in accordance to standards stated in Table 6. |
Illustration 19 | g06090892 |
Radiographic Testing |
Radiographic Testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength of electromagnetic radiation is used to penetrate materials to find hidden discontinuities such as cracks. In radiographic testing, the test object is placed between the radiation source and the film, or x-ray detector. The electromagnetic radiation will penetrate the thickness of the test object and, when all the way through, will project onto the film any indications that have been in the path of the radiation waves.
Heat Treatment
This welding procedure does not require a preheat or a postheat process. However, the cylinder block must be protected from cold weather. Store the cylinder block at room temperature. Room temperature is approximately
Basic Welding Process
Always follow these rules for welding to make a good repair to a cast iron cylinder block.
- Use an air carbon arc torch to remove two-thirds from the depth of the crack.
- Remove all sharp corners.
- Always clean the surface and prepare the surface before you start a weld pass. A clean surface is critical to a good weld.
- Always ignite the electrical arc on the weld. DO NOT ignite the electrical arc on the base metal (casting).
- Locate each end of the crack.
- Block the crack. Make a weld pass across each end of the crack to block the crack.
- When a pressurized area is repaired, use the correct electrode and the correct weld length.
- For a successful weld, verify that both the polarity and the amperage are in the correct position.
- Make the first weld pass. Butter the edges during the first weld pass. This method will form a ductile layer of transition to prevent cracks from progressing.
- Keep a short arc to maintain a voltage between 16 volts and 17 volts. Fill the crater at the end of each weld pass. Guide the electrode at a steep angle so that the welding arc is vertical.
- Stress can increase the length of a crack even after the first weld pass. If the crack progresses, locate the new end of the crack and block the crack again. Continue the welding procedure.
- Completely remove all slag from the weld after every weld pass.
- Peen the first weld before the weld cools.
- Allow the weld to cool before welding another pass.
- The weld must not be porous. If you suspect that oil has contaminated the weld, use a grinder to check for pores in the weld.
- The repair shall be free from cracks, porosity, undercut, and incomplete fusion. The weld quality must conform to the AWS D14.3 weld specifications. Blend the surface with a grinder and paint the surface after the repair has been made.
NOTICE |
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This welding procedure is referred to as cold welding. As previously stated, the temperature of the weld must be cooled to |
Note: Follow all surface preparation and cleaning procedures before you begin the repair. Refer to the section "Preparation of Joint and Surface According to Type of Damage". Once you have prepared the welding area, continue with the following instructions.
Note: A pure nickel welding rod may not work on some cast iron cylinder blocks. This can occur when glycol is present in the base metal. If so, use the following electrode and specifications when you weld.
- Use a UTP-85FN electrode with a
2.4 mm (0.09 inch) diameter when a pure nickel welding rod does not work. - Set the amperage of the welder to 70 amp.
- Set the polarity of the welder to DC REVERSE.
- Before welding on cast iron, always determine the correct polarity to get the desired results. Each electrode has a designated polarity. Use Table 4 to determine the polarity for the electrode. Also, refer to Table 4 to set the welder to the correct amperage. Refer to the following lists for additional information about each polarity.
Straight Polarity
- Shallow penetration
- Less heat input
- High weld due to less mixing of the base material
Reverse polarity
- More penetration
- Greater heat input
- Low weld due to more mixing of the base material
- Use the correct electrode for each type of weld. Use Table 4 to determine the correct electrode.
- The width of the weld must not be more than two times the wire diameter in the core of the electrode.
- The length of the weld must not exceed ten times the diameter of the welding electrode (
25.4 mm (1.00 inch) ). If the length of the weld is longer than the maximum length, the electrode may overheat. Use Table 4 to determine the maximum weld length. - Be sure to fill the crater at the end of each weld pass. This will help to prevent cracks from occurring at the end of the weld (crater cracks).
- Immediately after each weld pass has been made, peen the weld with a ball peen hammer. This will help to relieve the stress from the weld. Do not use air-actuated tools for this step. The exhaust from the tool can cool the weld too quickly. A rapid cooling rate will crack the weld.
- Allow the weld to cool to a temperature of
60 °C (140 °F) before cleaning the weld or before welding another pass. - Remove the slag from the weld. Then, use a stainless steel brush to remove the loose chips.
Note: Oil can produce pores in the weld during the first pass if the weld area was not clean prior to the weld pass. The first weld must not be porous. to test the weld joint for porosity, use an electric grinder with a rotary carbide steel cutter. Do not use a grinding wheel that has grit for the material.
- If there are pin holes in the weld, follow these steps.
- Use a grinder to remove one-third of the weld so that larger cavities can be seen. This will uncover pits or large cavities that could have been caused by oil contamination.
- Use a UTP-8 electrode with a
1.98 mm (0.078 inch) diameter to make the weld. Set the amperage to 45 amp. This will increase the strength of the weld. - Repeat this process if pin holes are still present in the weld. Remove only the porous layer and continue with the welding process.
Salvage Procedure for Welding Cracked Cast Engine Cylinder Blocks
Blocking a Crack
Perform this procedure when a crack has not completely advanced through the cylinder wall.
- Prepare the crack and clean the crack. Refer to the "Cleaning" section of this guideline. After you have cleaned the surface, check for cracks with one of the methods in the proper section of this guideline. Refer to the "Crack Detection Methods" section. This will ensure that all cracks have been found. This method will also help to determine if the true end of each crack has been correctly found.
- Block the crack. This will help to keep the crack from increasing in length.
- All welds must be perpendicular to the crack.
- Distance (F) between stringer welds (G) must not exceed
76 mm (3.0 inch) . Refer to Illustration 20.
- Locate each end of the crack. Measure the length of crack (F).
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Illustration 20 g06304254 - If the length of crack (F) is shorter than
76 mm (3.0 inch) , make a stringer weld (G) at each end of the crack. Each stringer weld must be perpendicular to the crack. Illustration 20 shows these welds. Make these weld beads25.4 mm (1.00 inch) to38 mm (1.5 inch) long.Show/hide tableIllustration 21 g06304257 - If the length of crack (H) above exceeds
76 mm (3.0 inch) , block the crack with two welds (J). - Divide the crack with as many stringer welds (K) as necessary. Make sure that no section of the crack is longer than
76 mm (3.0 inch) . This measurement is shown in location (L).
Welding a Crack
Note: Always use the welding electrode that is recommended for each specific application. Refer to Table 4 in the "Recommended Welding Electrodes" section.
- Block the crack.
- Once you have blocked the crack, begin the weld from the center of the crack. Weld from the center to the right. Then, weld from the center to the left.
- To avoid overheating, the length of each weld must not be more than ten times the diameter of the welding electrode. For this electrode, do not make a weld that is longer than
25.4 mm (1.00 inch) . - After each weld pass is made, immediately peen the weld. Allow the weld to cool before making the next weld pass.
- Continue to alternate weld passes between sections of the crack until one complete weld is made for the full length of the crack.
Cylinder Block that is Not Contaminated
Thickness of the Block Does Not Exceed
Illustration 22 | g06304264 |
Use one of the following electrodes for this weld.
Part | Diameter |
---|---|
UTP-8 Electrode | |
UTP-8-332 Electrode | |
UTP-8-18 Electrode | |
Make all welds to the correct length and in the numerical sequence shown.
Use one of the following electrodes for this weld. Set the amperage of the welder to 45 amp. This will increase the strength of the weld.
Part | Diameter |
---|---|
UTP-8 Electrode | |
UTP-8-332 Electrode | |
Thickness of the Block Exceeds
Illustration 23 | g06304266 |
For weld (1) through weld (9), use one of the following electrodes.
Part | Diameter |
UTP-8-564 Electrode | |
UTP-8-332 Electrode | |
UTP-8-18 Electrode | |
For weld (10) through weld (16), use one of the following electrodes.
Part | Diameter |
UTP-86FN-332 Electrode | |
UTP-86FN-18 Electrode | |
For weld (17) through weld (20), use the same welding electrode that was used for weld (1) through weld (9).
For weld (21), weld (22) and weld (23), use the same welding electrode that was used for weld (10) through weld (16).
Make all welds to the correct length and in the numerical sequence shown.
Cylinder Block that is Contaminated
Thickness of the Block does not Exceed
Illustration 24 | g06304269 |
Use one of the following electrodes to make this repair.
Make all welds to the correct length and in the numerical sequence shown.
Part | Diameter |
UTP-81-332 Electrode | |
UTP-81-18 Electrode | |
Thickness of the Block Exceeds
Illustration 25 | g06304266 |
For weld (1) through weld (9), use one of the following electrodes.
Part | Diameter |
UTP-81-332 Electrode | |
UTP-81-18 Electrode | |
Use one of the following electrodes for weld (10) through weld (16).
Part | Diameter |
UTP-86FN-332 Electrode | |
UTP-86FN-18 Electrode | |
Use one of the following electrodes for weld (17) through weld (19).
Part | Diameter |
UTP-8-564 Electrode | |
UTP-8-332 Electrode | |
UTP-8-18 Electrode | |
For weld (20) and weld (21), use one of the following electrodes.
Part | Diameter |
UTP-8-564 Electrode | |
UTP-8-332 Electrode | |
UTP-8-18 Electrode | |
For welds (22) and (23), use one of the following electrodes.
Part | Diameter |
UTP-86FN-332 Electrode | |
UTP-86FN-18 Electrode | |
Weld Repair for Missing Sections
Typically, when a cylinder block casting has a severe fracture or a complicated fracture, it is economical for you to first remove this area. Then weld a piece of mild steel plate into position. The thickness of the mild steel plate must not be more than 60 percent of the wall thickness. A piece of mild steel plate should NOT be rectangular in shape. A round shape or an oval shape is ideal for this steel plate. Weld at 90 degree intervals. Overheating will be reduced if you follow this sequence: top, bottom, right, and left. Make sure that each weld bead is short.
Note: If the shape of the steel plate must be rectangular, make sure that all corners of the steel plate are rounded as much as possible. Weld the sides first and weld the round corners last.
Missing sections may span critical angles or machined surfaces. It is possible to remove a good section, that is identical to the damaged section or the missing section, from another damaged cylinder block. The good section can then be welded into the missing section. All mating surfaces must be aligned during this welding procedure. After welding on the mounting surface of an oil pan, the seal must be airtight. Do not weld on an area that is critical to the structure of a block. These areas are shown in the following illustrations. DO NOT weld in these locations.
- Structural area
- Surfaces on the top deck
- Oil and/or water passages that would require welding from both sides
- Camshaft bearing surfaces and/or bores
Cylinder Block that is Not Contaminated
Thickness of the Block Does Not Exceed
Illustration 26 | g06304272 |
(M) Cylinder block
(N) Steel plate |
Use one of the following electrodes to make this repair.
Part | Diameter |
UTP-8-564 Electrode | |
UTP-8-332 Electrode | |
UTP-8-18 Electrode | |
Make all welds to the correct length and in the numerical sequence shown.
Thickness of the Block Exceeds
Illustration 27 | g06304275 |
(M) Cylinder block
(N) Steel plate |
- Use one of the following electrodes to weld in an identical cast iron section. For welds (1) through weld (3), use one of the following electrodes.
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Table 18 Part Diameter UTP-81-332 Electrode 2.4 mm (0.09 inch) UTP-81-18 Electrode 3.2 mm (0.13 inch) - Use one of the following electrodes to weld in a mild steel plate. For welds (4) through weld (6), use one of the following electrodes.
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Table 19 Part Diameter UTP-8-564 Electrode 1.9 mm (0.07 inch) UTP-8-332 Electrode 2.4 mm (0.09 inch) UTP-8-18 Electrode 3.2 mm (0.13 inch) - Use one of the following electrodes for weld (7) through weld (11).
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Table 20 Part Diameter UTP-8-564 Electrode 1.9 mm (0.07 inch) UTP-8-332 Electrode 2.4 mm (0.09 inch) UTP-8-18 Electrode 3.2 mm (0.13 inch) - Use one of the following electrodes for weld (12) through weld (14).
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Table 21 Part Diameter UTP-86FN-332 Electrode 2.4 mm (0.09 inch) UTP-86FN-18 Electrode 3.2 mm (0.13 inch) - Repeat steps 3 and 4 until the weld is complete.
Make all welds to the correct length.
Cylinder Block that is Contaminated
Thickness of the Block Does Not Exceed
Illustration 28 | g06304278 |
(M) Cylinder block
(N) Steel plate |
Use one of the following electrodes to weld in an identical cast iron section for weld (3) through weld (4).
Part | Diameter |
UTP-81-332 Electrode | |
UTP-81-18 Electrode | |
Make all welds to the correct length.
Use one of the following electrodes to weld in a mild steel plate for welds (1), (2) and (5).
Part | Diameter |
UTP-8-564 Electrode | |
UTP-8-332 Electrode | |
UTP-8-18 Electrode | |
Make all welds to the correct length.
Thickness of the Block Exceeds
Illustration 29 | g06304280 |
(M) Cylinder block
(N) Steel plate |
- Use one of the following welding rods to weld in an identical cast iron section. Use one of the following electrodes for weld (1) through weld (3).
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Table 24 Part Diameter UTP-81-332 Electrode 2.4 mm (0.09 inch) UTP-81-18 Electrode 3.2 mm (0.13 inch) - Use one of the following welding rods to weld in a mild steel plate. Use one of the following electrodes for weld (4) through weld (6).
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Table 25 Part Diameter UTP-8-564 Electrode 1.9 mm (0.07 inch) UTP-8-332 Electrode 2.4 mm (0.09 inch) UTP-8-18 Electrode 3.2 mm (0.13 inch) - Use one of the following welding rods for this welding procedure. Use one of the following electrodes for weld (7) through weld (11).
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Table 26 Part Diameter UTP-8-564 Electrode 1.9 mm (0.07 inch) UTP-8-332 Electrode 2.4 mm (0.09 inch) UTP-8-18 Electrode 3.2 mm (0.13 inch) - Use one of the following welding rods for this welding procedure. Use one of the following electrodes for weld (12) through weld (14).
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Table 27 Part Diameter UTP-86FN-332 Electrode 2.4 mm (0.09 inch) UTP-86FN-18 Electrode 3.2 mm (0.13 inch) - Continue the repair by alternating steps 3 and 4 until the weld area is filled with welding material.
Make all welds to the correct length.
Final Checks
- Grind the weld. The weld must be flush with the cylinder block.
- Apply the cleaner, the penetrant and the developer.
Note: Never use magnaflux to check a nickel weld on a cast iron cylinder block. This test will reveal the crack that has been repaired. Always use the dye-penetrant to check for cracks.
- If cracks or pin holes appear in the welded area, grind out the faulty section and perform the welding procedure again, until an acceptable solid repair is completed.
Repairing a Cylinder Block with an Oil Porosity
Examples of Damage
Illustration 30 | g06304296 |
Source of cylinder block oil porosity (arrow) |
Illustration 31 | g06304297 |
Source of cylinder block oil porosity (arrow) |
The Illustration 30 and Illustration 31 show the examples of the source of oil leakage on a cylinder block. A salvage repair for this type of damage is possible using the procedure given in this publication.
Explanation of Repair Procedure
The type of repair procedure demonstrated in this publication is accomplished with the use of pipe plugs or special pins.
Pipe Plugs
Illustration 32 | g06304298 |
Typical example of a pipe plug. |
The pipe plugs have a thread pitch diameter that is tapered and create a pressure tight, metal-to-metal fit.
Special Pins
Illustration 33 | g06304299 |
Ironstich pin |
The pins have an oversized thread pitch diameter that gives a pressure tight, metal-to-metal fit. (The initial threads are tapered to aid in pin installation.)
The non-threaded shoulder, which is located above the threads, crushes into the upper threads of the casting, creating a metal-to-metal seal.
The tapered thread, along with the break-off groove that is located above the shoulder, controls the break-off torque to insure the uniformity of the installation depth.
Cleaning and Inspection of Casting
The casting that is to be repaired must be degreased completely and thoroughly cleaned by using a pressure washer or steam cleaner.
Repair Procedure
Note: The procedure shown in this instruction was performed with the engine out of chassis.
This procedure can be performed with the engine in chassis providing that the necessary components are removed to access the area to be repaired.
Illustration 34 | g06304300 |
Preparing the surface |
- To prepare the casting for repair, use a suitable tool to remove any paint from the area.
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Illustration 35 g06304296 Example of marked area - Use a hammer and center punch to mark the casting prior to drilling.
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Illustration 36 g06304304 Greased paper towel in place - Apply grease to a suitable rag or paper towel. Place the towel or the rag in the cylinder block at the repair site that will trap metal particles created in the following steps.
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Illustration 37 g06304308 Pin, Tap, and drill bit - Select the proper size drill bit and tap for the size of plug or pin that is to be installed.
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Illustration 38 g06304311 Drilling the hole - Carefully drill the hole in the cylinder block.
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Illustration 39 g06304313 Tapping the hole - Apply grease to the tap to trap the metal particles. Apply penetrating oil to the hole drilled in the cylinder block in Step 5. Cut threads in the hole to install the plug or the pin.
- Remove the rag or paper towel and the remaining grease from inside the cylinder block.
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Illustration 40 g06304314 Cleaning the threads - Use a suitable cleaning fluid to clean the threads that were cut in Step 6.
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Illustration 41 g06304315 Drying the threads - Use compressed air to dry the threads.
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Illustration 42 g06304318 - Applying thread lock to the pin
- If the special pin is used, apply 9S-3263 Thread Lock Compound to the threads.
- If a pipe plug is used, apply 154-9731 Thread Lock Compound to the threads.
Show/hide tableIllustration 43 g06304319 Pin installed in tapped hole Show/hide tableIllustration 44 g06304320 Tighten the pin Show/hide tableIllustration 45 g06304321 Installed pin (head separated) - Install the plug or the pin.
- If a pin is used, then tighten the pin until the pin head separates from the pin body.
- If a plug is used, then tighten the plug to the torque found in chart A.
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Table 28 Chart A
Torque for Pipe PlugsPipe Thread Size Recommended Torque 1/16 10 N·m (7 lb ft) 1/8 16 N·m (12 lb ft) 1/4 20 N·m (15 lb ft) 3/8 35 N·m (26 lb ft) 1/2 45 N·m (33 lb ft) 3/4 60 N·m (44 lb ft) 1 75 N·m (55 lb ft)
Show/hide tableIllustration 46 g06304323 Grinding the pin flush Show/hide tableIllustration 47 g06304324 Example of pin ground flush - Grind off the pin or the plug until flush with the casting surface.
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Illustration 48 g06304326 Pin peening the area Show/hide tableIllustration 49 g06304327 Example of pin peened area - Use a suitable tool to pin peen the repaired area, to help relieve stresses and aid in sealing.
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Illustration 50 g06304328 Pin extending into the cylinder block - Check to ensure that the amount of the pin or the plug that extends into the cylinder block will not interfere with the rotating components of the engine.
Test Procedure
After a repair is complete, a test should be performed to make sure that there is good seal. The two acceptable testing methods are listed below.
Soap and Water
Apply air pressure to the inside of the repaired area. Put a soap and water solution on the opposite side. Soap bubbles will appear if the repaired area has a leak.
Dye Penetrant
Repaired areas should be tested by applying dye penetrant to one side of the repair. The penetrant will soak through if a leak exists.
Illustration 51 | g06304329 |
Completed repair |
After the testing is completed, the repaired area can be cleaned and painted to give a nearly invisible repair, as shown in Illustration 51
Reinstall the components that were removed to perform the repair.