Reuse and Salvage for 3200 Engine Cylinder Blocks {1201} Caterpillar

Caterpillar Products

All 3200 Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF9121
2–3	Combined information from SEBF2120, SEBF2121, SEBF8201, and repaired 4 pixelated illustrations.
01	The following part numbers have been removed from this document 263-7140, 263-7141, 263-7142, 263-7145, 263-7258, and 263-7259.

© 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.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This guideline has the specifications for reusability of cylinder blocks that are used on the 3200 family of engines. If a cylinder block meets the specifications that are found in this guideline, then the cylinder block can be expected to give normal performance until the next overhaul when the cylinder block is used again in the same application.

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

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"
SEBF8162	Reuse and Salvage Guidelines, "Reuse and Salvage for Cylinder Head Assemblies"
, 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	Reuse and Salvage Guideline "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	Special Instruction, "Using the 6V-7840 Deck Checking Tool Assembly"
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"

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.

Table 3

Required Tooling and Equipment
Part Number	Description
1P-3537	Dial Bore Gauge Kit
1U-9366	Automatic Tape Measure
1U-9915	Curved Handle Wire Brush
4C-4804	Penetrant
4C-9442	Flashlight
4S-9405	Caliper
5P-3920	Steel Ruler
5P-7414	Seal Pick
6V-2010	Polishing Stone
6V-2012	Depth Micrometer
8S-2257	Eye Loupe
8T-0455	Liner Projection Tool Group
6V-7840	Deck Checking Tool
8S-3140	Counterboring Tool Group
8T-5096	Dial Indicator Group
8T-7765	Surface Reconditioning Pad
9A-1593	Comparison Gauge
9U-6182	Inspection Mirror
174-6858	Cleaner
254-5319	Surface Condition Brush
262-8390	Microscope, Pocket 40x
263-7184	Crack Detection Kit
288-4209	Paper Towel
303-9339	Lint Free Shop Towels
367-9109	Digital Caliper
385-4008	Micrometer Tool Set, External 1524 mm (60 inch)
385-9422	Micrometer Extensions, Internal 50 - 609 mm (2 - 24 inch)
386-3364	Straight Edge
415-4055	Ultrasonic Tool Group
420-5317	Tool Cribbing
423-4373	Digital Caliper 0.0 - 203.2 mm (0.00 - 8.00 inch)
431-4150	Micrometer, External 25 mm (1 inch)
448-3698	Profilometer
459-0184	UV Lamp Group
473-8688 or 473-8689	Micrometer, Inside 2.00 - 12.00 inch
	Micrometer, Inside 50 - 300 mm
473-8690	Micrometer, Outside 0.00 - 4.00 inch
473-8691	Micrometer, Outside 2.00 - 6.00 inch
473-8691	Micrometer, Outside 50.8 - 152.4 mm (2.00 - 6.00 inch)
473-8692	Micrometer, Outside 152.4 - 304.8 mm (6.00 - 12.00 inch)
474-3709 or 474-3710	Micrometer, Inside (8.00 - 32.00 inch)
	Micrometer, Inside 200 - 800 mm
-	Radial Drill(1)
-	FFB5SP010K Full Torque Thread Insert Kit (1/2 inch Thread)
-	L750G Tapping Fluid
-	LHC724 Sealant

(1)	Drilling Speed of the Spindle is 146 rpm, tapping Speed of the Spindle is 45 rpm, and the Rate of the Feed of the Drill is 0.006 per revolution.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Measurement Requirements

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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

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.

Cylinder Liner Projection

Illustration 4	g06307445

Use 8T-0455 Liner Projection Tool Group to check the projection of the cylinder liner after the cylinder block has been reconditioned. Refer to the Service Manual of the engine for the correct liner projection.

The cylinder block can be machined and shimmed if the liner projection is not with specifications. Shims should be avoided, when possible. The projection of the liner will decrease sooner when shims are used instead of inserts. Also, future repairs will be less difficult if inserts are used instead of shims.

Inserts for the liner can also be used to restore the cylinder liner to the correct height.

Surface Texture

Surfaces that have been machined must be smooth to form a good seal. The machined finish for the top deck of the cylinder block must be 3.2 µm (125 µinch) or less for the engines listed on this document.

Reconditioning Dimensions

3200 Engines (Direct Injection)

The specifications for the original dimensions and the minimum reconditioned dimensions are shown in Table 4.

Measure the projection of the piston when the reconditioned cylinder blocks are used. The pistons must extend above the top deck of the cylinder block 0.51 ± 0.51 mm (0.020 ± 0.020 in).

Note: The projection of the piston does not include the tolerance stackup from rod bearing clearances, the crankshaft, the bushing for the rod eye, and the piston.

When the engine is reconditioned, both the cylinder block and the head must be checked. Refer to Reuse and Salvage Guidelines, SEBF8162, "Reuse and Salvage for Cylinder Head Assemblies" for additional information on the cylinder head. This information covers thickness of the cylinder head and the projection of the intake and exhaust valves.

Marking the Reconditioned Block

Keep an exact record of the amount and location of the stock that is removed from the cylinder block. Mark the cylinder block near the changed surface. Do not mark the cylinder block in the area of the gasket seal. Refer to Reuse and Salvage Guidelines, SEBF8187, "Standardized Parts Marking Procedures" for additional information on marking parts.

These 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 machine history. The machining that is performed should also be reported in Service Information Management System (SIMS).

Specifications

Tables 4 contain the specifications for the measurements that need to be taken during reconditioning of the cylinder block.

Note: The dimensions assume that no material has been removed from the rail for the valve cover and the centerline of the crankshaft has not been raised. The specifications will need to be adjusted accordingly if machining has already occurred.

Table 4

Specifications for the 3200 Cylinder Block
Engine Model	New Height of the Cylinder Block	Minimum Height of the Cylinder Block	Flatness of the Top Deck
3200(1)	322.66 ± 0.13 mm (12.703 ± 0.005 inch)	322.40 mm (12.693 inch)	0.15 mm (0.006 inch) overall 0.08 mm (0.003 inch) for any 152 mm (6.0 inch) span
3204(2)	322.66 ± 0.13 mm (12.703 ± 0.005 inch)	322.40 mm (12.693 inch)	0.15 mm (0.006 inch) overall 0.08 mm (0.003 inch) for any 152 mm (6.0 inch) span

(1)	Direct Injection
(2)	Precombustion

Inspection Procedure for Top Deck Cracks in 3208 Engines

This procedure is to visually inspect the top deck in 3208 Engine. The cracks are between the water port and cylinder head bolt hole. This procedure will determine if the cylinder block can be used again.

Visual Inspection

Illustration 5	g06307460
Typical top deck of a cylinder block on 3208 Engines. Small cracks in areas indicated by arrows are acceptable.

Illustration 6	g06307469
Close-up of a typical crack in top deck of 3208 cylinder block. Crack is between water port and cylinder head bolt hole. (1) Water Port (2) Crack (3) Cylinder Head Bolt Hole (4) Chamfer

Illustration 7	g06307475
Depth of crack must not extend below depth of chamfer.

Note: Caterpillar has approved the use of 3208 cylinder blocks with a crack between the water port and the cylinder head bolt hole. However, crack (2) must not extend below the depth of the bolt hole chamfer (4). See Illustration 7.

Procedure for Cylinder Head Bolt Holes for 3208 Engines

Visual Inspection

Blocks should be visually inspected for cracks before the repair procedure is used.

Check the top deck of the block for cracks. Refer to "Crack Detection Methods" section for more information on crack detection. The cracks must be no deeper than 6.4 mm (0.25 inch) down the counterbore of the bolt hole. The cracks cannot run into the cylinders. The cracks must only run into water jackets. The number of cracks per hole does not matter. Mark all bad holes with a paint pen.

Full-Torque Threaded Inserts

This guideline will provide a repair procedure for cracked bolt holes and stripped bolt holes on a 3208 Engine. The procedure utilizes Lock-N-Stitch products that were introduced in Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair". Full Torque Thread Insert Kits are used to repair the cracked bolt holes and stripped bolt holes. Refer to the "Procedure for Cylinder Head Bolt Holes for 3208 Engines" section of this guideline for information. The threaded inserts and the parts that accompany the threaded inserts that are included in this guideline are included in FFB5SP010K Full Torque Thread Insert Kit from LOCK-N-STITCH. These parts can be ordered through LOCK-N-STITCH. Refer to Reuse and Salvage Guideline, SEBF8882, "Using Lock-N-Stitch Procedures for Casting Repair" for other LOCK-N-STITCH parts that are stocked by Caterpillar. All other parts in this guideline can be ordered through the Caterpillar distribution network.

Installing a Threaded Insert can be done in a short amount of time. Installing a Threaded Insert will increase the strength of the threads. This guideline will cover the proper procedure for repairing damaged bolt holes with Threaded Inserts on 3208 Blocks.

Illustration 8	g06307487
Full-Torque Threaded Inserts

This is a new concept in repairing threaded holes.

All bolts and studs produce a significant radial force that spreads when the bolts and studs are torqued. In metals with low strength such as cast iron, brass, and aluminum, this force that spreads often results in cracks. During repair work, most cracks are found in threaded holes. Cracked bolt holes can be repaired by using Full-Torque Threaded Inserts. Threads that are stripped can be repaired by using Full-Torque Threaded Inserts.

Full-Torque Threaded Inserts use unique external threads. These inserts will contain the force of the fastener. These inserts will only transfer radial force to the surrounding material. This force will draw the surrounding material together.

Full-Torque Threaded Inserts are available in the style of through hole and the style of blind hole. Threaded Inserts are available with shoulders and without shoulders. Solid plugs are available to repair badly damaged holes. After installing the plug, a new hole can be drilled and tapped in the proper location.

Procedure

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Illustration 9	g01304315

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Illustration 10	g01312592

1. Secure the block on the table for the drill with an angle iron to avoid spinning the block. Use threaded stock to hold the block down to the table.
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   Illustration 11	g01317519

2. Center the drill over the hole.

3. Clamp the drill into position.
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   Illustration 12	g01317522

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   Illustration 13	g01317525

4. Use the 21/32 inch drill (FT5DB-1 from LOCK-N-STITCH). Use a stop collar to set the depth of the drill to a depth of 35.687 mm (1.40 inch). Be sure that the shoulder on the drill bit touches the top deck of the block when you drill the hole.

5. Remove the drill bit. Replace with the FT5FT Tap from LOCK-N-STITCH
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   Illustration 14	g01317611

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   Illustration 15	g01324814

6. Remove all metal shavings from the hole.
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   Illustration 16	g01317622

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   Illustration 17	g01317646

7. Tap the hole with the FT5FT Tap from LOCK-N-STITCH. Apply L750G tapping fluid from LOCK-N-STITCH to the tap while you are tapping.

8. Tap the hole again with the FT5FT Tap from LOCK-N-STITCH by using your hands.

   Note: The Tap must bottom in the hole.

9. Remove all metal shavings from the hole.

10. Remove the burrs from the hole with a file.
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    Illustration 18	g01317663

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    Illustration 19	g01317659

11. Clean the hole and the insert by using component cleaner to remove all the oil and the metal shavings.
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    Illustration 20	g01317664

12. Apply a liberal amount of LHC724 Sealant from LOCK-N-STITCH to the insert and the hole.
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    Illustration 21	g01317668

13. Install the Threaded Insert by using the FP51213K Insert Installation Tool from LOCK-N-STITCH.

    Note: See the instructions in FFB5SP010K Full Torque Thread Insert Kit (1/2 inch Thread) from LOCK-N-STITCH for instructions on assembling the FP51213K Insert Installation Tool.

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    Illustration 22	g01317670

14. Torque the insert until the washer on the installation tool is flush with the deck of the block.

15. Remove the FP51213K Insert Installation Tool from the insert.
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    Illustration 23	g01317673

16. Clean the hole and the surface.

Crack Detection Methods

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NOTICE
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.

Table 5

Crack Inspection Method Advantages vs. Disadvantages
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 0.13 mm (0.005 inch)	- 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

Table 6

Applicable Crack Detection Standards
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 24	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 24. It is suggested that at a minimum personnel performing Visual Inspection are either trained to a company standard or have sufficient 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 regularly.

Liquid Penetrant Testing (PT)

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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

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Illustration 25	g06107074
Typical example of pre-cleaning area.

1. 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 26	g06107081
   Typical example of applying penetrant.

2. 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 27	g06107088
   Typical example of removing excess penetrant oil.

3. 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 28	g06107094
   Typical example of applying developer.

4. 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.
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   Illustration 29	g06084042
   Typical example of cracks found during a liquid penetrant testing.

5. 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 29. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 30	g06085930
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (C) Dry powder bulb.

1. 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.

2. 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.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

4. 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).

5. 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.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. 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.

6. Observe particles and note if any clusters of particles appear revealing an indication.

7. 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 31	g06085937
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process.

Illustration 32	g06003178
Pear Shaped Centrifuge Tube

1. 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.

2. Concentration:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 32. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. 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.

   5. 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.

3. 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

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

2. Apply the magnetic field using the yoke against the surface in the area to be inspected.

3. 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.

4. Visually inspect for indications of discontinuities using the proper illumination.

5. 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.

Show/hide table

NOTICE
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.

1. 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.

2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.

   1. 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.

   2. 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)

Show/hide table

NOTICE
All personnel involved in Eddy-Current Testing shall be qualified to Level 2 in accordance to standards stated in Table 6.

Illustration 33	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.

Show/hide table

NOTICE
All personnel involved in radiographic testing shall be qualified to Level 2 in accordance to standards stated in Table 6.

Illustration 34	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.

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

Table 7

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

Table 8

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

Show/hide table

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

Table 9

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.
	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

Show/hide table

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.

Table 10

Flame Spray Process (6P-II)	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 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
	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.
	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
	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

Illustration 35	g06370992

Part Description

Table 11

Base Metal	Cast Iron
Hardness	N/A

Arc Spray Equipment and Procedure

Table 12

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

Table 13

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

Table 14

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

Table 15

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 36.

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 37.

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

Illustration 36	g06278538
Example of protection for a component that is stored for a shorter term

Illustration 37	g06278539
Example of protection for a component that is stored for a longer period