Reuse and Salvage for 3000 Engine Series Cylinder Blocks {1201} Caterpillar

Reuse and Salvage for 3000 Engine Series Cylinder Blocks {1201}

Usage:

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Caterpillar Products: All 3000 Engines

Introduction

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Table 1
Revision	Summary of Changes in SEBF9069
07	Added new serial number prefixes for New Product Introduction (NPI).
06	Combined information from SEBF2120, SEBF2121, SEBF8818, SEBF9049, SEBF9070, SEBF9071, and repaired 18 pixelated illustrations.

© 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 not 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

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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.

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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 includes specifications, inspection, and salvage information for 3044, 3046, 3054, 3056, 3064 and 3066 Cylinder Blocks.

Before reusing a cylinder block assembly, check for leaks, cracks, and flatness. All components of the cylinder block must meet the recommended specifications in this guideline before being reused.

Service Letters and Technical Information Bulletins

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NOTICE

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

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Table 2
References
Media Number	Title
M0080689	Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure"
SEBF8148	Reuse and Salvage Guidelines, "General Salvage and Reconditioning Techniques"
SEBF8187	"Standardized Parts Marking Procedures"
SEBF8301	Reuse and Salvage Guidelines, "Inspection and Reuse of Critical Fasteners Used in All Engines"
SEBF8357	Reuse and Salvage Guidelines, "General Cleaning Methods"
SEBF8882	"Using Lock-N-Stitch Procedures for Casting Repair"
SEBF9238	Reuse and Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240	Reuse and Salvage Guidelines, "Fundamentals of Flame Spray for Reconditioning Components"
SEHS8187	"Using the 6V-7840 Deck Checking Tool"
SEHS8869	"Cylinder Block Salvage Procedure Using Belzona® 1311 Ceramic R Metal"
SEHS8919	"Salvage Procedure for Cast Iron Cylinder Blocks"
SEHS9031	"Storage Procedures for Caterpillar Products"
SEPD0705	"A Piston Sleeve is Available to Repair the 3046 Engine Block"

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.

Tooling and Equipment

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NOTICE

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.

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Table 3
Required Tooling and Equipment
Part Number	Description
1D-5119	Nut
1P-0820	Hydraulic Puller
1P-2392	Puller Plate
1P-2402	Gauge Body
1P-2403	Dial indicator
1P-3537	Dial Bore Gauge
1P-4000	Line Boring Tool
1U-6142	Belzona Kit for Repair of the Block
1U-7234	Feeler Gauge
2P-5486	Gauge Block
4B-9820	Wrench
5H-1504	Hard Washer
5P-2170	Dial Bore Gauge
6B-7225	Wrench
6V-2183	Forcing Screw
6V-7840	Deck Checking Tool Assembly
7B-0337	Surface Plate
7B-7640	Wrench
9U-6142	Puller Plate
486-1526	Degreaser
367-9109	Digital Caliper

Measurement Requirements

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NOTICE

Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Initial Cleaning of the Engine

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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.

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NOTICE

All reconditioned components should be cleaned again before assembly. Any debris or residue on the parts such as metal chips, carbon deposits, or sludge can enter the system. Debris or residue can cause early engine failures.

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 replace all 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.

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NOTICE

Failure to remove all dirt, debris, and/or metal shavings from openings, ports, and passages, will result in damage to the engine and the related components. A cylinder block that is not cleaned thoroughly will result in piston seizure or rapid wear of the cylinder bores, pistons, and piston rings. Only the thorough use of a rotary brush will correctly remove abrasive particles. The following table lists the maximum permitted contaminant levels for the finished machined cylinder block.

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Table 4
Contaminant Levels
Feature	Max Contaminant Weight (mg), Cpk = 1.33	Max Particulate Size in any Direction (µm)
All the main bearing cap surfaces including the butt faces, bolt holes and the main bearing cap bolt holes after machining has been completed.	20	-
Oil passage holes	40	500
All cylinder bores	4	-
All lubricated surfaces of the cylinder block. This includes the pushrod apertures, chamber for the lifters, bearing caps, and bolts.	86	-
Main bearing cap butt faces, bolt holes and bolts. All surfaces after machining.	60	-
Water jacket	100	-
Filtration level - 30 µm

Reconditioning Suggestions

The following is a list of suggestions that are for common problems that can occur when the cylinder block is being reconditioned.

The area around the cylinder sleeve can sometimes be polished by the slight movements between the cylinder sleeve and the block. This polished surface is sometimes seen as erosion. If the measurable erosion is not more than 0.03 mm (0.001 inch), there is no need to shave the top deck. The cylinder sleeve needs to be flush with the top of the block.
The best way to salvage minor erosion that is at a depth of 0.13 mm (0.005 inch) or more depth that is on the top deck of the cylinder block use the Belzona® kit for the affected area.

Critical Factors for Reconditioning the Cylinder Blocks

There are several factors that affect the amount of material that can be removed from the surface of the component. The factors include the valve and projections of the cylinder sleeve and the mating surface flatness. The other factors that should be included are backlash of the timing gear and surface texture. When you are reconditioning the mating surfaces of the block and head be sure to measure the areas as well as the dimensions for the minimum thickness of the cylinder blocks.

In all the following reconditioning procedures, remove the minimum material that is necessary to make the repair.

Note: The dimensions assume that the centerline of the crankshaft has not been raised. Adjust the specifications accordingly if the machining has already occurred.

Surface Texture

The machined surface must be smooth to form a good seal. The machined finish that is between the cylinder head and the block must meet specifications.

Dimensions for Reconditioning

Note: When you are reconditioning the block, remove the minimum amount of material that is necessary to make the repair.

If a block is machined, the projection of the sleeve must be checked during assembly and also adjusted to the correct specifications.

When you are reconditioning an engine, both the block and head must be checked.

Marking the Reconditioned Block

Keep exact records on the amount of stock and the location of stock that was removed from the engine. Mark the block or stamp the block near the changed surface, but not in an area of the gasket seal. For additional information on the marking of the parts, refer to Reuse and Salvage Guide, SEBF8187, "Standardized Parts Marking Procedures".

The markings could also have code letters for the dealer and/or the machine shop. Write all this information in the Service Report for the engine history or the history of the vehicle. Write a report in the Service Information Management System (SIMS) to describe the machining that was performed on the engine.

General Specifications

Warpage of the Cylinder Block

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Illustration 4	g06337213
(1) Cylinder Block

Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge. The maximum allowable clearance is 0.05 mm (0.002 inch). Resurface the top of the block if the maximum repair limit of 0.20 mm (0.008 inch) is reached.

Main Bearing Bores

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Illustration 5	g06337217
(2) Bearing Cap (3) Dial Bore Gauge

Install the main bearing caps before the measurement of the bore is performed. This dimension is used after the crankshaft is removed and bearing caps are assembled and tightened according to specifications in the service manual. Measure the inside diameter of the bearing in the positions that are shown in the Illustration 5 to get an average measurement by using the 1P-3537 Dial Bore Gauge. Measure the outside diameter of the crankshaft journal. If the clearance of the two measurements does not meet the specifications, replace the main bearing, or use the undersize bearings for the crankshaft. Take note of any irregular wear patterns on the crankshaft or bearing. The irregular wear patterns can be a good indication of problems with alignment in the components.

Crankshaft End Play

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Illustration 6	g01244768
(4) Dial indicator

Measure the crankshaft end play with the thrust plates that are installed on the front side and the rear side on the rear main cap and the main bearing caps that are tightened to the specified torque. The end play is the difference between the width of the journal and the width of the thrust plate and bearing cap.

Note: Generally, the rear side thrust plate is likely to be worn more rapidly than the front journal. If necessary, replace the rear thrust plate.

Camshaft Bore

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Illustration 7	g06337224
(5) Camshaft bearing

Measure the camshaft bearing with a dial indicator.

3044, 3046, 3064, and 3066

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Illustration 8	g06337208
Cylinder block. (A) Minimum distance from centerline of crankshaft bore to top surface of cylinder block (B) Diameter of the bore for the piston (C) Bore for camshaft bearing (D) Width of main bearing cap (E) Bearing dimension (F) Dimension from centerline of crankshaft bore to pan rail

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Table 5
Dimensions for the Cylinder Block
Sales Model	3044, 3046	3064, 3066
(A) Minimum distance from centerline of crankshaft bore to top surface of cylinder block	294.96 mm (11.613 inch)	306.95 mm (12.085 inch)
(B) Diameter of the bore for the piston	97.972 ± 0.017 mm (3.8572 ± 0.0007 inch)	104.973 ± 0.018 mm (4.1328 ± 0.0007 inch)
(B) Inside diameter of the bore for the piston	94.017 ± 0.017 mm (3.7014 ± 0.0007 inch)	102.027 ± 0.017 mm (4.0168 ± 0.0007 inch)
(C) Bore for front camshaft bearing	54.04 ± 0.010 mm (2.128 ± 0.0004 inch)	57.009 ± 0.009 mm (2.2444 ± 0.0004 inch)
(C) Bore for camshaft bearing	54.04 ± 0.010 mm (2.128 ± 0.0004 inch)	57.009 ± 0.009 mm (2.2444 ± 0.0004 inch)
(C) Bore for the rear camshaft bearing	53.04 ± 0.010 mm (2.088 ± 0.0004 inch)	57.009 ± 0.009 mm (2.2444 ± 0.0004 inch)
(D) Width of main bearing cap	27.0 mm (1.06 inch)	28.0 mm (1.10 inch)
(F) Torque of the bearing cap	103 ± 5 N·m (76.0 ± 3.7 lb ft)	137 ± 5 N·m (101.0 ± 3.7 lb ft)
(E) Clearance between bearing and journal	0.080 ± 0.030 mm (0.0031 ± 0.0012 inch)	0.084 ± 0.034 mm (0.0033 ± 0.0013 inch)
(E) The repair limit of clearance between bearing and journal	0.200 mm (0.0079 inch)	0.200 mm (0.0079 inch)
(G) Measurement from centerline of crankshaft bore to pan rail	75.0 mm (2.95 inch)	80.0 mm (3.15 inch)

3054, 3054B, 3054C, 3054E, 3056, and 3056E

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Illustration 9	g06337336
Bottom view of 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)

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

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Illustration 10	g06337337

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Table 6
Item	Description	Dimension
(E)	Top Deck Surface Texture	Average ≤ 15 µm (5.9055 µinch) Max ≤ 20 µm (7.8740 µinch)
(E)	Flatness of Top Deck	0.05-0.025 / 100 x 100
(F)	3054 / 3056 / 3056E⁽¹⁾
	New Bore	104.204 mm (4.1025 inch) to 104.229 mm (4.1035 inch)
	3054B
	New Bore	103.000 mm (4.0551 inch) to 103.025 mm (4.0561 inch)
	First Oversize Bore	103.500 mm (4.0748 inch) to 103.525 mm (4.0758 inch)
	Second Oversize Bore	104.000 mm (4.0948 inch) to 104.025 mm (4.0955 inch)
	3054C/ 3056E
	New Bore	105.000 mm (4.1338 inch) to 105.025 mm (4.1348 inch)
	Oversize Bore	105.500 mm (4.1535 inch) to 105.525 mm (4.1545 inch)
(G)	Top Deck Height of NEW Block	352.27 mm (13.869 inch) to 352.37 mm (13.873 inch)
(G)	Top Deck Height After Skim Cut	352.024 mm (13.8592 inch) to 352.124 mm (13.8631 inch)

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⁽¹⁾	Liner engine with no oversize bore.

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Table 7
3054 & 3056 Series Cylinder Blocks Dimensions for Cylinder Blocks:
	3054 & 3056	3054B	3054C	3054E	3056E
Diameter of the Bore for the Cylinder Sleeve	100.00 mm (3.937 inch)	103.00 mm (4.055 inch)	N/A	N/A	100.00 mm (3.937 inch)
Cylinder Sleeve Outer Diameter	104.265 ± 0.015 mm (4.105 ± 0.0006 inch)	No Sleeve	No Sleeve	No Sleeve	104.265 ± 0.015 mm (4.105 ± 0.0006 inch)
Bore in Cylinder Block for the Main Bearing	80.429 ± 0.013 mm (3.167 ± 0.0005 inch)	80.429 ± 0.013 mm (3.1667 ± 0.0005 inch)	80.429 ± 0.013 mm (3.1667 ± 0.0005 inch)	80.429 ± 0.013 mm (3.1667 ± 0.0005 inch)	80.429 ± 0.013 mm (3.1667 ± 0.0005 inch)
Orientation of Baffle Plate to the Vertical Plane⁽¹⁾	± 5°	± 5°	± 5°	± 5°	± 5°
Depth of the Plug from face of Cylinder Block	3.0 mm (0.12 inch)	3.0 mm (0.12 inch)	3.0 mm (0.12 inch)	3.0 mm (0.12 inch)	3.0 mm (0.12 inch)
Depth of Recess for Cylinder Sleeve Flange	3.86 ± 0.05 mm (0.152 ± 0.002 inch)	No Sleeve	No Sleeve	No Sleeve	3.86 ± 0.05 mm (0.152 ± 0.002 inch)
Diameter of the Recess for Cylinder Sleeve Flange	107.885 ± 0.065 mm (4.247 ± 0.003 inch)	No Sleeve	No Sleeve	No Sleeve	107.885 ± 0.065 mm (4.247 ± 0.003 inch)
Tighten bolt that holds Cooling Jet	27 N·m (20 lb ft)	27 N·m (20 lb ft)	27 N·m (20 lb ft)	27 N·m (20 lb ft)	27 N·m (20 lb ft)

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⁽¹⁾	The baffle plates on the new type "D" plug must be fitted horizontally and vertically to within ± 5°. This will ensure the maximum performance of the baffle plates

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Table 8
Diameter Dimensions for Camshaft Bearings
Engine Size	Dimensions
Four-cylinder Engine
Inside diameter of the camshaft bearing for the number 1 camshaft journal	50.79 to 50.85 mm (2.000 to 2.002 inch)
Bore diameter in the cylinder block for the number 1 camshaft bearing	55.56 to 55.59 mm (2.187 to 2.189 inch)
Bore diameter in the cylinder block for the number 2 camshaft journal	50.55 to 50.60 mm (1.990 to 1.992 inch)
Bore diameter in the cylinder block for the number 3 camshaft journal	50.04 to 50.09 mm (1.970 to 1.972 inch)
Six-cylinder engine
Inside diameter of the camshaft bearing for the number 1 camshaft journal	50.79 to 50.85 mm (2.000 to 2.002 inch)
Bore diameter in the cylinder block for the number 1 camshaft bearing	55.56 to 55.59 mm (2.187 to 2.189 inch)
Bore diameter in the cylinder block for the number 2 camshaft journal	50.55 to 50.60 mm (1.990 to 1.992 inch)
Bore diameter in the cylinder block for the number 3 camshaft journal	50.29 to 50.34 mm (1.980 to 1.982 inch)
Bore diameter in the cylinder block for the number 4 camshaft journal	50.04 to 50.09 mm (1.970 to 1.972 inch)

Repair Damage to the Block

There are several methods of casting repair that are available, dependent on the type of damage to the block. Carefully follow the recommended Special Instructions for each method. Each method that is described below has a special application. Use only the method that is approved in the application.

Cast Iron Welding

A new cold welding procedure has been developed by Caterpillar which permits the repair of Caterpillar castings. Special welding rods of high nickel alloy are available through Caterpillar, required for a successful repair. The part numbers for the electrode and the Instructions for welding non-structural cracks are given in the Special Instruction, SEHS8919, "Salvage Procedure for Cast Iron Cylinder Blocks".

Lock-N-Stitch

Using the Lock-N-Stitch repair kits that are available from Caterpillar may be able to repair the holes that are caused by a single failure of the rod or cracks in a casting. These repairs should not be made in structural areas. The repair method that is utilized can achieve a permanent repair. The detailed instructions and the part numbers for the kit can be found in the Special Instruction, SEBF8882, "Using the Lock-N-Stitch Procedures for Casting Salvage".

Belzona® 1311 Ceramic R Metal

The mixed material can be used to repair porosity or pitting of the block. The composite material can only be used in the applications that are outlined because of the low material strength that is compared with welding and Lock-n-stitch. Instructions for obtaining the material and the application of material can be found in Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure for Using Belzona® 1311 Ceramic R Metal".

The block needs to be thoroughly cleaned after each of the above repair methods. The repair of the block that is using Belzona® products cannot be placed in the strong caustic material at an elevated temperature. Using strong caustic material may soften the material of the repair.

Height of Top Deck of the Block

Use the 6V-7840 Deck Checking Tool to measure the height of top deck of the block. Refer to the Special Instruction, SEHS8187, "Using the 6V-7840 Deck Checking Tool", for more information about this tool group.

Available Tooling

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Illustration 11	g03412760

6V-7840 Deck Checking Tool assembly includes the following tools. 4B-7640 Wrench, 7B-7640 Wrench, and 6B-7225 Wrenches

Repairing Block Top Deck with Metal Spray

A metal spray process can also be used to restore the contact surfaces to the original dimensions. Refer to "Thermal Spray Procedures for Top Surface Deck", for information about metal spray repair procedures.

Line Boring the Cylinder Block

Tooling

Use 1P-4000 Line Boring Tool Group to perform the line bore operation. Refer to Special Instruction, SMHS7606, "Use Of 1P4000 Line Boring Tool Group", describes the use of this tool.

Centering Rings

Standard centering rings and oversized centering rings must be purchased.

Changes to Boring Procedure

Follow the procedure in Special Instruction, SMHS7606, "Use Of 1P4000 Line Boring Tool Group" and use the special centering rings.

Place the centering rings, with oiler up, on each side of the cap being replaced. For an end cap, place the centering rings in the second and fifth bearing bores.

In the procedure for setting up the boring bar, tighten the bolts on bearing caps that have centering rings from 27 N·m (20 lb ft) minimum to 70 N·m (50 lb ft) maximum while rotating the boring bar to check for binding. All other bearing cap bolts should be tightened to the specifications in the Service Manual.

When setting the tool bit, place it in the holder, and set the micrometer 1.78 mm (0.070 inch) less than the finished bore diameter found in Table 7. This setting depends on whether a standard or oversized centering ring will be used. Verify the dimension after machining and before bearing caps are removed.

Boring the Cylinder Block for Piston Sleeves or Oversize Pistons

Piston Sleeve for the 3044 and 3046 Engine Block

If a cylinder bore has a defect or excessive wear, a piston sleeve is available for repair. Use 122-7311 Piston Sleeve to repair the cylinder bore. Use the following procedure to install the piston sleeve.

Set up a boring bar toevenly remove material from the cylinder walls.
The cylinder bore that is getting replaced must be bored to install the piston sleeve. The inside diameter of the cylinder bore should be 97.955 mm (3.8565 inch) to 97.990 mm (3.8579 inch).
Cool the piston sleeve to 0 °C (32.0 °F).
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Illustration 12 g06337242

(1) Forcing Screw
(2) Hydraulic Puller
(3) Cylinder Sleeve
(4) Puller Plate
(5) Nut
(6) Cylinder Block
(7) Puller Plate
Install a new piston sleeve. Use the Sleeve Installer to install a replacement sleeve.
Press the piston sleeve into the cylinder block until the distance between the top of the piston sleeve and the top of the block is 0.30 mm (0.012 inch).
Mill the top of the piston sleeve until the piston sleeve is flush with the top of the cylinder block.
Bore the piston sleeve to a diameter of 94.000 mm (3.7008 inch) to 94.035 mm (3.7022 inch).
Hone the piston sleeve to a surface texture of 0.4 µm (15.75 µinch) to 0.8 µm (31.50 µinch).

Piston Sleeve for the 3064 and 3066 Engine Block

Visually inspect the cylinder bore. There should be no scoring, rust, or corrosion.
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Illustration 13 g06337249

(4) Cylinder Sleeve
Measure the cylinder bore at the upper, middle, and lower areas in the direction of the crankshaft and at a right angle to the crankshaft.
Note: The “Upper area” that is described above corresponds to the top ring when the piston is at Top Dead Center (TDC). The “lower area” corresponds to the piston oil ring when the piston is at the Bottom Dead Center (BDC).
Check the bore by using a 1P-3537 Dial Bore Gauge. Refer to Table 9 for the correct cylinder bore size.
If the cylinder bore is not within the specifications in Table 9, the cylinders bore needs to be machined to an oversized piston. Reference the following machining procedure to machine a cylinder block for an oversized piston.
Note: Refer to Table 9 for the correct dimensions.
1. Machine the cylinder block to the correct preliminary dimension of the bore for the oversized piston.
2. Perform the first honing procedure by using a diamond hone and then hone the cylinder bore to the correct dimension.
3. Perform the second honing procedure by using a silicone carbide base hone and then hone the cylinder bore to the correct dimension.
4. Perform the final honing procedure by using a silicone carbide plateau hone and then hone the cylinder bore to the correct dimension.

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Table 9
Specifications for Cylinder Bore of the Oversize Piston on the 3044, 3046 Engines
Description	Cylinder Bore		Surface Texture	Maximum Roundness and Taper	Hone Angle
Description	Minimum Dimension	Maximum Dimension	Surface Texture	Maximum Roundness and Taper	Hone Angle
First Oversize Piston 0.250 mm (0.0098 inch)
Preliminary Bore Size	94.123 mm (3.7056 inch)	94.174 mm (3.7076 inch)	3.50 µm (.137.7853 µinch)	0.020 mm (0.0008 inch)	N/A
Diamond hone	94.199 mm (3.7086 inch)	94.211 mm (3.7091 inch)	2.50 µm (98.425 µinch)	0.012 mm (0.0005 inch)	35°
Silicone Carbide Base Hone	94.250 mm (3.7106 inch)	94.275 mm (3.7116 inch)	1.60 µm (62.9921 µinch)	0.010 mm (0.0004 inch)	35°
Silicone Carbide Plateau Hone	94.250 mm (3.7106 inch)	94.275 mm (3.7116 inch)	0.80 µm (31.49606 µinch)	N/A	N/A
Second Oversize Piston 0.50 mm (0.020 inch)
Preliminary Bore Size	94.373 mm (3.7155 inch)	94.424 mm (3.7175 inch)	3.50 µm (.137.7853 µinch)	0.020 mm (0.0008 inch)	N/A
Diamond hone	94.449 mm (3.7185 inch)	94.461 mm (3.7189 inch)	2.50 µm (98.425 µinch)	0.012 mm (0.0005 inch)	35°
Silicone Carbide Base Hone	94.500 mm (3.7205 inch)	94.525 mm (3.7214 inch)	1.60 µm (62.9921 µinch)	0.010 mm (0.0004 inch)	35°
Silicone Carbide Plateau Hone	94.500 mm (3.7205 inch)	94.525 mm (3.7214 inch)	0.80 µm (31.49606 µinch)	N/A	N/A
Specifications for Cylinder Bore of the Oversize Piston on the 3064, 3066 Engines
First Oversize Piston 0.250 mm (0.0098 inch)
Preliminary Bore Size	102.123 mm (4.0206 inch)	102.174 mm (4.0226 inch)	3.50 µm (.137.7853 µinch)	0.020 mm (0.0008 inch)	N/A
Diamond hone	102.199 mm (4.0236 inch)	102.275 mm (4.0266 inch)	2.50 µm (98.425 µinch)	0.012 mm (0.0005 inch)	35°
Silicone Carbide Base Hone	102.250 mm (4.0256 inch)	102.275 mm (4.0266 inch)	1.60 µm (62.9921 µinch)	0.010 mm (0.0004 inch)	35°
Silicone Carbide Plateau Hone	102.250 mm (4.0256 inch)	102.275 mm (4.0266 inch)	0.80 µm (31.49606 µinch)	N/A	N/A
Second Oversize Piston 0.50 mm (0.020 inch)
Preliminary Bore Size	102.373 mm (4.0304 inch)	102.424 mm (4.0324 inch)	3.50 µm (.137.7853 µinch)	0.020 mm (0.0008 inch)	N/A
Diamond hone	102.449 mm (4.0334 inch)	102.461 mm (4.0339 inch)	2.50 µm (98.425 µinch)	0.012 mm (0.0005 inch)	35°
Silicone Carbide Base Hone	102.500 mm (4.0354 inch)	102.525 mm (4.0364 inch)	1.60 µm (62.9921 µinch)	0.010 mm (0.0004 inch)	35°
Silicone Carbide Plateau Hone	102.500 mm (4.0354 inch)	102.525 mm (4.0364 inch)	0.80 µm (31.49606 µinch)	N/A	N/A

Parent Bore Block for the 3054, 3054B, 3054C, 3054E, 3056, and 3056E Engine Block

If the top deck surface of the cylinder block requires machining, then the top deck must be machined prior to boring the cylinders. The top deck height is measured from the center line of the main bearing bore to the top deck surface of the engine block.

After milling the top deck, then the cylinder bores will need to be chamfered, piston projection will need to be inspected, and a thicker head gasket will need to be used. Refer to Table 10 for head gasket part number information.

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Table 10
Head Gaskets
Part Number	Cylinder Bore / Piston Size	Top Deck Height
310-8520 (Standard Gasket)	Standard Bore and Piston and 0.5 mm (0.020 inch) Oversized Piston	Standard Dimensions
369-3707 ( 0.25 mm (0.010 inch) Thicker Gasket)	Standard Bore and Piston and 0.5 mm (0.020 inch) Oversized Piston	Used when 0.25 mm (0.010 inch) is removed from the top deck surface.
396-4482	0.5 mm (0.020 inch) Oversized Piston Kit

When 0.25 mm (0.010 inch) is removed from the top deck surface, the projection of the piston should then be 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

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

The parent bore block can be bored for oversize pistons. This procedure is for parent bore blocks only, not liner bore blocks. Careful attention must be addressed to bore diameter, surface texture, and replacing the chamfer at the top of the cylinder bore.

Cylinders can be bored 0.5 mm (0.02 inch) oversized. 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 6.

Visually inspect the cylinder bore. There should be no scoring, rust, or corrosion.
Measure the cylinder bore at the upper, middle, and lower areas (piston ring contact area).
Note: The "upper area" described above corresponds to the top ring when the piston is at Top Dead Center (T.D.C.). The "lower area" corresponds to the piston oil ring when the piston is at Bottom Dead Center (B.D.C.).
Check the bore using a cylinder bore gauge. Refer to Table 7 for the correct cylinder bore size.
If the cylinder bore is not within specification, the cylinder bore must be machined oversize. Perform the following procedure when machining the cylinder block to accept an oversize piston.
Note: Refer to Table 11 for the correct dimensions.
1. Machine the cylinder block to the correct oversize piston preliminary bore size dimension.
2. Perform the first honing procedure using a diamond hone, hone the cylinder bore to the correct dimension
3. Perform the second honing procedure using a silicone carbide base hone, hone the cylinder bore to the correct dimension
4. Perform the third and final honing procedure using a silicone carbide plateau hone, hone the cylinder bore to the correct dimension

To ensure emissions compliance following engine overhaul, Caterpillar recommends that only cylinder blocks that meet the specifications detailed in this article are to be used.
Ensure that the honing specification in this article is met. The honing specification is critical to oil control and ultimately emissions compliance. Caterpillar recommends that if the required honing specification cannot be met, either a new cylinder block, new Cat engine, or a Cat Reman engine must be used to ensure emissions compliance.
A chamfer must be added to the top of the bores of the cylinder block. Refer to the section "Cylinder Bore Chamfers" within this document.

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.

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Table 11
Parameter	Limit
Rpk	< 0.2 µm (0.01 µinch)
Rk	0.2 µm (0.01 µinch) to 0.6 µm (0.02 µinch)-
Rvk	0.8 µm (0.03 µinch) to 1.8 µm (0.07 µinch)
Mr1	<10%
Mr2	65-85%

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 crosshatch of the honing finish 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.

Cylinder Bore Chamfers

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

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Illustration 14	g06337351

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Table 12
Chamfer Dimensions
(J)	15°-17°
(K)	0.2 mm (0.008 inch) to 0.5 mm (0.02 inch)

Replacement of the Cylinder Sleeve for the 3064 and 3066

Replace all cylinder sleeves that exceed the service limit of 102.700 mm (4.0433 inch).

Use the following procedure to repair the cylinder sleeves.

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Illustration 15	g06337254
(5) Cylinder Sleeve

Set up a boring machine on the cylinder block. Align the boring machine with the center of the bottom of the cylinder sleeve with the less worn area.
Bore the sleeve until the thickness is 0.50 mm (0.020 inch).
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Illustration 16 g06337260
Remove the remainder of the sleeve. Be careful not to damage the cylinder block.
Install a new sleeve. Use the Sleeve Installer to install a replacement sleeve.
Install the sleeve into the cylinder block and leave a sleeve projection of 0.30 mm (0.012 inch) to 0.50 mm (0.020 inch) at the top of the block. Then make the sleeve flush with the top of the cylinder block.
Bore the sleeve and hone the sleeve to the correct specifications.

Gear Group

3044, 3046

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Illustration 17	g06337266
(6) Camshaft gear (7) Fuel injection pump gear (8) Crankshaft gear (9) Oil pump gear (10) Idler gear

Tighten the nut for the fuel injection pump drive gear to the following torque 83 to 98 N·m (61.2 to 72.3 lb ft).

Tighten the nut for the idler gear to the following torque 29 to 39 N·m (21.4 to 28.8 lb ft).

3064, 3066

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Illustration 18	g06337269
(11) Fuel injection pump gear (12) Idler gear (13) Camshaft gear (14) Crankshaft gear (15) Nut for fuel injection pump drive gear

Tighten the nut for the fuel injection pump drive gear to the following torque 83 to 98 N·m (61.2 to 72.3 lb ft).

Tighten the nut for the idler gear to the following torque 29 to 39 N·m (21.4 to 28.8 lb ft).

Timing Gears

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Illustration 19	g06337276
(16) Timing marks for the fuel injection pump gear (17) Timing marks for the idler gear (18) Timing marks for the camshaft gear (19) Timing marks for the crankshaft gear

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Illustration 20	g06337278
Fuel Injection Pump Timing Mark (20) Timing marks (21) Timing marks

End Play and Backlash

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Table 13
Specification of End Play and Backlash
Description	Standard at Assembly	Service Limit
End play of camshaft	0.10 to 0.25 mm (0.004 to 0.010 inch)	0.300 mm (0.0118 inch)
End play of idler gear	0.05 to 0.20 mm (0.002 to 0.008 inch)	0.35 mm (0.014 inch)
Timing gear Backlash	0.03 to 0.18 mm (0.001 to 0.007 inch)	0.350 mm (0.0138 inch)
Crankshaft end play	0.100 to 0.264 mm (0.0039 to 0.0104 inch)	0.300 mm (0.0118 inch)
Backlash of oil pump gear and idler gear	0.10 to 0.19 mm (0.004 to 0.007 inch)	0.35 mm (0.014 inch)

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Illustration 21	g06337281
(22) Dial Indicator

Measure the end play with dial indicator (22). Refer to Table 13 for the specification of the end play of the gear, that was measured.

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Illustration 22	g06337284
The illustration shows the correct position of the dial indicator to measure timing gear backlash. Keep the tip of the dial indicator at 90 degrees to the centerline of the tooth or as close as possible.

Reference Table 13 for the minimum of relative movement for the backlash that is available. Check for the backlash of the gear in three or four locations on the gear. The small difference in the gear teeth and the runout of the gear tooth make checking at different locations necessary. To check the backlash of the gear, hold one gear steady and use the dial indicator to measure the relative movement of the one gear to the other gear. The dial position is important for a correct accurate reading.

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

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Table 14
Minimum Surface Texture Before Spray	3.2 µm (125.9843 µinch)
Reason for Spraying	Restore deck height to specification
Arc Spray Equipment Type	SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 75B Wire or equivalent Nickel Aluminum Wire
Max Spray Thickness	2.0 mm (0.08 inch) (Should Target 0.60 mm (0.024 inch) to 1.20 mm (0.05 inch) Spray Thickness)
Spray Angle	90°
Substrate Pre-Heat Temperature	22.2 °C (72.00°F) to 66°C (150.8°F) Do not direct arc on area to be sprayed.
Substrate Temperature During Spraying Not to Exceed	148°C (300°F)
Surface Preparation Method	Grit blast - If the entire mating surface is to be arc sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating, and can reduce material cost and finish machining time.

	Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Machining Method	Milling
Equipment Required	Rottler 99Y or similar
Recommended Cutting Tool	Sandvik R245 12T 3MPM 1010
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Finishing Equipment Type	Milling
Finishing Equipment	Rottler 99Y or similar

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Table 15
Arc Spray		Procedure		Check List
Clean Part		Pre-machine block and degrease block deck surface.
		Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Undercut		Must not exceed 2.0 mm (0.08 inch) spray thickness
Chamfer		All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm (0.020 inch) chamfer.
Remove Oxide		Use fiber flap brush or Clean/strip disc
Clean Spray Area		Commercial degreaser ( Methyl Alcohol or Acetone)
Mask for Grit Blast		Grit blast - If the entire mating surface is to be arc sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating and can reduce material cost and finish grinding time.
		Precautions and care must be taken to properly mask and remove all grit from block surface and cavities.
Grit 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 mm (2.0 inch) to 150 mm (6.0 inch)
Remove Blast Mask		Make sure that surface is clean
		Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Mask for Metal Spray		Tape, Metal Shield, Rubber, Metco Antibond, etc.
Metal Spray Equipment Type		Smart Arc by Oerlikon Metco	TAFA
	Consumable	TAFA 75B or Equivalent	TAFA 75B or Equivalent
	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)	152.4 mm (6.0 inch)	152.4 mm (6.0 inch)
	Approx. Spray Rate/Pass	0.08 mm (0.003 inch)/pass	0.08 mm (0.003 inch)/pass
Gun Fixturing Method		Machine mount or hand held
Traverse Rate of Gun		395.00 mm/s (1.296 Ft/s)
Finishing Equipment		Rottler 99Y or similar
Part/Cutter Rotation (Roughing)		Roughing 50 SMPM (150 SFPM)
Part/Cutter Rotation (Finishing)		Finishing 75 SMPM (250 SFPM)
Traverse Speed		0.30 mm (0.012 inch) per revolution
Depth of Rough Cut		0.51 mm (0.020 inch) per side max First pass should remove at least 0.178 mm (0.007 inch) to get below the peaks of the spray.
Depth of Finish Cut		0.25 mm (0.010 inch) per side max

Flame Spray Equipment and Procedure

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NOTICE

Flame spray is not a validated or approved process for spraying under top supported liner flanges.

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Table 16
Minimum Surface Texture Before Spray	3.2 µm (125.9843 µinch)
Reason for Spraying	Wear, erosion, center line distance too short to rework
Oerlikon Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 453
Finish Thickness	As required 0.25 mm (0.010 inch) to 0.38 mm (0.015 inch)
Finishing Allowance	Machine 0.64 mm (0.025 inch)
Spray Angle	90°
Substrate Pre-Heat Temperature	22.2°C (72.00°F) to 66°C (150°F)
Substrate Temperature During Spraying Not to Exceed	204°C (400°F)
Surface Preparation Method	Grit blast - If the entire mating surface is to be flame sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating, and can reduce material cost and finish machining time.
Surface Preparation Method	Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Finishing Method	Machine
Grinding Equipment Type	Standard head and block grinder
Recommended Wheel	Norton 23A30E12VBEP or SGL abrasive HSA24F13-VKP
Machining Equipment Type	Mill
Recommended Cutter Grade	Sandvik 310-K-10 LNCX

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NOTICE

Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.

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Table 17
Flame Spray Process (6P-II)	Procedure	Check List
Clean Part	Pre-machine block and degrease block deck surface.
Clean Part	Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Undercut	Must not exceed 1.5 mm (0.06 inch) spray thickness
Chamfer	All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm (0.020 inch) chamfer.
Remove Oxide	Use fiber flap brush or Clean/strip disc
Remove Oxide	Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Clean Spray Area	Metco cleaning solvent or equivalent
Mask for Grit Blast	Grit blast - If the entire mating surface is to be flame sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating, and can reduce material cost and finish machining time.
Mask for Grit Blast	Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Grit 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	50 mm (2.0 inch) to 150 mm (6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
Remove Blast Mask	Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Mask for Metal Spray	Tape, Metal Shield, Rubber, Metco Antibond, etc.
Metal Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Nozzle	6P-C7A-K "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling Air 140 kPa (20.0 psi) to 170 kPa (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 (12.00 lb) per hour 0.10 mm (0.004 inch) to 0.15 mm (0.006 inch) per pass
Gun to Work Distance	178 mm (7.0 inch)
Traverse Rate of Gun	36 SMPM (120.0 SFPM)
Gun Fixturing Method	Machine mount or hand held
Per Pass Thickness	0.10 mm (0.004 inch) to 0.15 mm (0.006 inch) per pass
Finishing Equipment	Standard head and block grinder, Milling machine
Part/Cutter Rotation	92.0 SMPM (300.00 SFPM)
Traverse Speed	Rough 203 mm (8.0 inch) per minute finish 38.1 mm (1.5 inch) to 51.0 mm (2.01 inch) per minute
Depth of Rough Cut	0.03 mm (0.001 inch) to 0.05 mm (0.002 inch) 0.25 mm (0.010 inch) to 0.38 mm (0.015 inch)
Depth of Finish Cut	0.03 mm (0.001 inch) 0.13 mm (0.005 inch) to 0.25 mm (0.010 inch)

Thermal Spray Procedures for Crankshaft Main Bearing Saddle Area

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Illustration 23	g06370992

Part Description

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Table 18
Base Metal	Cast Iron
Hardness	N/A

Arc Spray Equipment and Procedure

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Table 19
Maximum Surface Texture	1.6 µm (62.99213 µinch)
Reason for Spraying	Bearing Failure
Mating Part Contact Area & Material	Crankshaft main bearing
Arc Spray Equipment Type	SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 30T Wire Top Coat, TAFA 75B Wire Bond Coat
Finish Thickness	As required
Spray Angle	90°
Substrate Pre-Heat Temperature	66.0° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148.0° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Hand held
Surface Preparation Method	Undercut and grit blast
Machining Method	Line bore
Recommended Cutting Tool	ISCAR DNMG 432 TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Finishing Equipment Type	Line boring machine

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Table 20
Arc Spray		Procedure		Check List
Clean Part		Degrease in hot caustic solution
Undercut		Not required
Chamfer		All edges - 45° to 0.08 mm (0.0030 inch)
Remove Oxide		Use fiber flap brush or Clean/strip disc
Clean Spray Area		Commercial degreaser
Mask for Grit Blast		Use a metal mask or duct tape
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 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask		Make sure that surface is clean
Mask for Metal Spray		Antibond or Blue Layout Dye
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	0.0023 mm (0.00009 inch)/pass	0.0023 mm (0.00009 inch)/pass
	Traverse Rate of Gun	11 SMPM (36 SFPM)
Gun Fixturing Method		Hand held
Finishing Equipment		Line boring machine
Part/Cutter Rotation (Roughing)		Roughing 50 SMPM (150 SFPM)
Part/Cutter Rotation (Finishing)		Finishing 75 SMPM (250 SFPM)
Coolant		Oil based synthetic - 40:1 ratio
Traverse Speed		0.30 mm (0.012 inch) per revolution
Depth of Rough Cut		0.51 mm (0.020 inch) per side max
Depth of Finish Cut		0.25 mm (0.010 inch) per side max
Additional Finish Method		Flex hone if necessary

Flame Spray Equipment and Procedure

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Table 21
Maximum Surface Texture	1.6 µm (62.99213 µinch)
Reason for Spraying	Bearing failure
Mating Part Contact Area & Material	Crankshaft main bearing
Oerlikon Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 453 Grind 463
Finish Thickness	As required
Finishing Allowance	0.51 mm (0.020 inch) per side
Spray Angle	90° to bore
Substrate Pre-Heat Temperature	38° C (100° F)
Substrate Temperature During Spraying Not to Exceed	149° C (300° F)
Auxiliary Cooling	If desired
Rotation/Traverse Device	Hand held
Rotation/Traverse Speed	15 SMPM (50 SFPM)
Surface Preparation Method	Grit Blast
Finishing Method	Machine
Recommended Wheel	Norton 23A30E12VBEP or SGL abrasive HSA24F13-VKP
Machining Equipment Type	Line Boring Machine
Recommended Cutter Grade	ISCAR DNMG 432 TFIC507

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Table 22
Flame Spray Process (6P-II)	Procedure	Check List
Clean Part	Degrease in hot caustic solution
Undercut	Not required
Chamfer	All edges - 45° to 0.08 mm (0.030 inch)
Remove Oxide	Use die grinder or flapper wheel
Clean Spray Area	Metco cleaning solvent or equivalent
Mask for Grit Blast	Use metal mask or duct tape
Grit 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 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
Mask for Metal Spray	Metco Anti-Bond or blue layout dye
Metal Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Auxiliary Cooling	If desired
Nozzle	6P-7CA-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 (12.00 lb) per hour 0.10 - 0.15 mm (0.004 - 0.006 inch) per pass
Gun to Work Distance	230 mm (9.0 inch)
Rotation Speed of Part (RPM)	N/A
Rotation Speed of Part	N/A
Traverse Rate of Gun	15 SMPM (50.00 SFPM)
Gun Fixturing Method	Hand held
Bond Pass/Thickness	0.13 mm (0.005 inch)
Top Coat/Thickness	As required
Finishing Equipment	Line boring machine
Part/Cutter Rotation	46 to 55 SMPM (150.0 to 180.0 SFPM)
Traverse Speed	0.08 mm (0.003 inch) or less
Depth of Rough Cut	0.25 mm to 0.51 mm (0.010 inch to 0.020 inch)
Depth of Finish Cut	0.13 mm to 0.25 mm (0.005 inch to 0.010 inch)
Additional Finish Method	Flex hone if necessary

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 24.

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 25.

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

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