Reuse Specifications for 3600 Combustion Gaskets {0762, 0763, 1100, 1124, 1201} Caterpillar

Caterpillar Products

All 3600 Engines

All C280 Engines

All G3600 Engines

Introduction

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

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

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may 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

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.

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

Information is given in this guideline for inspecting and measuring used combustion gaskets. Information is also included for identifying gaskets and usage. A used combustion gasket must be inspected for the surface texture, flatness, parallelism, roundness, thickness, and corrosion.

Service Letters and Technical Information Bulletins

Tooling and Equipment

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Measurement Requirements

Cleaning

Before inspecting and measuring, the gasket must be cleaned. use a Scotch Brite pad to remove any buildup of debris or carbon. Do not use an abrasive material that will remove the base metal.

Surface Texture

The gasket surface must be free of nicks, gouges, and any damage that may result in leakage. Some corrosion on the sealing surfaces is acceptable, but the corrosion is limited to 5.0 mm (0.20 inch) across the surface. This corrosion is shown in Figure 3. Gaskets with corrosion that is extending completely across the sealing surface must not be reused. The sealing surface must be at least 1.6 µm (63 µinch).

Procedure to Measure Combustion Gaskets

All the measurements should be taken 15 to 30 times at intervals of 12 to 24 degrees around the gasket. These values should then be compared to each other and the values must fall within the tolerance that is given in table 4. The use of outside and inside micrometers is recommended to obtain accurate thickness (parallelism) and measurements of roundness.

Flatness

Place the gasket on a surface plate to measure the flatness. Use a 0.038 mm (0.0015 inch) feeler gauge to check the full diameter of the gasket for any spaces between the gasket and the surface plate. If the flatness exceeds the specifications in table 4, the gasket should not be reused.

Thickness and Parallelism

Record the measurements of the thickness around the diameter according to the given measurement procedure. If any measurement is under the “Minimum for Reuse” specification in table 4, do not reuse the gasket.

To check for parallelism, subtract each measurement of thickness from the previous measurement. The difference between these two measurements must fall within the specifications for “parallelism” that are shown in table 4.

Roundness

Record the inside diameter of the gasket according to the given measurement procedure. The difference between any two measurements must be within 0.3 mm (0.012 inch). These measurements should be taken without stress on the gasket. Do not take measurements in areas that have wear from corrosion on the surface.

Illustration 3	g06181701
(A) The maximum allowable wear from corrosion is 5.0 mm (0.20 inch).

Illustration 4	g06181702
A sketch that shows the design of the cross section for each gasket according to the part number. This sketch is not to scale.

Illustration 5	g06181703
The detail of the design of the area (B) for the gasket seat on liners. Notice the radius at the face on the early stages of design for the liner. (1) Early design for the liner (2) New design for the liner

Detail and Usage

The detail of the design for the gasket that is shown in figure 4 can help identify used gaskets that have unreadable part numbers. See table 4 for specifications on thickness.

The detail of the area for the seat of the gasket on the liners is shown in figure 5. Some of the early designs for the liners are still in production.

The new 142-2826 Combustion Gasket and 179-4382 Gasket do not have a chamfer on the inside diameter. Refer to figure 4. These gaskets will not seat properly on early designs of liners because of the radius at the intersection of the face for the liner. For this reason, the gaskets must be used on new designs for liners only. See table 5for complete information on applications for each gasket.

Liners that are new and liners that are discontinued may be used in the same engine, but either the 145-7230 Combustion Gasket or the 166-7083 Gasket should be used on all liners. The side of the gasket with the large chamfer must be against the face of the liner when the 145-7230 Combustion Gasket or the 166-7083 Gasket is being installed on older liners.

The 3606 engine and the 3608 engine are subject to rapid changes in power demands because of usage in harbor tugs and marine vessels that handle anchors. Engine serial numbers after 8RB825 and after 6MC6461 should use the 179-3168 Liner due to rapid changes in power demands.