Reuse and Salvage for 3114, 3116, and 3126 Engine Series Cylinder Blocks {1201} Caterpillar


Reuse and Salvage for 3114, 3116, and 3126 Engine Series Cylinder Blocks {1201}

Usage:

D6D 01Y
Caterpillar Products
All 3100 Engines

Introduction

Table 1
Revision  Summary of Changes in SEBF8192 
10  Added sleeve installation. 
Combined information from SEBF2120, SEBF2121, SEBF2122, SEBF8167, SEBF8261, SEBF8277, SEBF8960, and repaired 36 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



Illustration 1g02139237

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, or operating technique is not recommended by Caterpillar, ensure that it is safe for you and for other people. 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.

------ WARNING! ------

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 2g00008666

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 3114, 3116, 3126 Engine Series 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


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 
GMG00981  Special Instruction, "Using 1P3537 Dial Bore Group to Check Cylinder Bore Size" 
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  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  Special Instruction, "Cylinder Block Salvage Procedure Using Belzona® 1311 Ceramic R Metal" 
SEHS8919  Reuse and Salvage Guideline, "Reuse and Salvage for Cast Iron Cylinder Blocks" 
SEHS9031  Special Instruction, "Storage Procedures for Caterpillar Products" 
SEHS9047  Special Instruction, "Installation of 7C-6208 Cylinder Sleeve" 
SEHS9120  Special Instruction, "Using the 127-3458 Sleeve Replacement Tool Group" 
SMHS7606  Special Instruction, "Use Of 1P-4000 Line Boring Tool Group" 

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

------ WARNING! ------

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


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 
1D-5119  Nut 
1P-0820  Hydraulic Puller 
1P-2329  Insert 
1P-2392  Puller Plate 
1P-2402  Gauge Body 
1P-2403  Dial indicator 
1P-3537  Dial Bore Gauge 
1P-3565  Chamfering Tool 
1P-4000  Line Boring Tool 
1P-5580  Brush 
1U-7234  Feeler Gauge 
1U-7428  Flexible Hone 
1U-7429  Brush 
2P-5486  Gauge Block 
4B-9820  Wrench 
4C-4377  Cylinder Head Stress Plate (1) 
4C-4804  Penetrant 
4C-6336  Flexible Hone 
4C-9765  Center Rings 
5H-1504  Washer 
5P-2170  Dial Bore Gauge 
6B-7225  Wrench 
6V-2033  Brush 
6V-2183  Forcing Screw 
6V-7840  Deck Checking Tool Assembly 
7B-0337  Surface Plate 
7B-7640  Wrench 
7C-6208  Cylinder Sleeve 
8T-0450  Thread Identification Kit 
9S-6072  Adjusting Crank 
9S-6074  Adjusting Screw 
9S-7338  Cross Block 
9U-6007  Puller Plate 
9U-6008  Puller Plate 
9U-6142  Puller Plate 
107-7604  Cylinder Sleeve 
125-2064  Cylinder Head Stress Plate (1) 
126-8132  Cylinder Head Stress Plate (1) 
129-9196  Puller Plate 
129-9197  Puller Plate 
142-2285  Cylinder Head Stress Plate (1) 
174-6858  Cleaner 
263-7184  Crack Detection Kit 
288-4209  Cylinder Head Stress Plate 
459-0184  UV Lamp Group 
486-1526  Degreaser 
367-9109  Digital Caliper 
93028 (2)  Digital Disc Brake Calipers 
Rottler Model F2VB (3) 
Rottler Model FA2AVB (3) 
Sunnen CK-10 (3) 
Sunnen CK-616 (3) 
Rottler Model HP3 (3) 
Rottler Model HP3A (3) 
(1) Stress plate is used only during measuring and honing of the cylinder sleeve bore. Do not use the stress plate during the block boring procedure.
(2) Cen-Tech part number
(3) Any of the following tools are acceptable for use in this procedure.

Note: In addition to the tools listed in the table, a STANDARD thickness cylinder head gasket must be used with 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines) during the honing cycle. The cylinder head gasket may be reused several times with the stress plate, however a new gasket must be used during the final cylinder head installation.

Refer to the Parts Manual for the correct STANDARD thickness cylinder head gasket.

Measurement Requirements


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 3g06238164

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.

------ WARNING! ------

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.



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

Cleaning the Cylinder Block

One of the major reasons for a bearing failure after an engine overhaul is damage caused by debris in the oil passages. Remove all dirt, debris, and metal shavings from all openings, ports, and passages. Refer to M0080689 Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure" for cylinder block cleaning.


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.


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.

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.

Repairing Block Top Deck with Thermal Spray

A thermal 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 thermal spray repair procedures.

General Specifications

Flatness of the Top Deck



Illustration 4g06337213
(1) Cylinder Block

Measure the amount of the warpage of the cylinder block with a straight edge 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



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

The main bearing caps should be installed and tightened to the torque. Check the size of main bearing bore by using the 1P-3537 Dial Bore Gauge.

If the main bearing bore does not measure 95.000 ± 0.038 mm (3.740 ± 0.0015 inch) for 3114, 3116, and 3126 Engines, replace the main bearing cap. This dimension is used after the crankshaft is removed and bearing caps are assembled and tightened according to specifications in the service manual. It will be necessary to line bore new replacement bearing caps.

Camshaft Bore



Illustration 6g06337224
(5) Camshaft bearing

Measure the camshaft bearing with a dial indicator.



Illustration 7g06338260
(C) Centerline of crankshaft bore to top of block
(D) Cylinder bore size
(E) Bore for FRONT camshaft bearing only
(F) Width of main bearing cap
(G) Bore for main bearings
(H) Centerline of crankshaft bore to pan rail
(1) Oil hole in cam bearing
(2) Oil hole in block for front camshaft bearing
(3) Main bearing cap bolts
(4) Location of the sequence number of the bearing cap

Table 4
Dimensions of the Front Face 
Callout  Dimensions for 3114 and 3116 sales models  3126 Dimension 
322.000 ± 0.170 mm (12.6771 ± 0.0067 inch) 
D (1)  105.025 ± 0.025 mm (4.1348 ± 0.0010 inch)  110.025 + 0.025 - 0.010 mm (4.3317 + 0.0010 - 0.00039 inch) 
70.000 ± 0.025 mm (2.7559 ± 0.0010 inch) 
159.995 ± 0.020 mm (6.2990 ± 0.0008 inch) 
95.000 ± 0.013 mm (3.7402 ± 0.0005 inch) 
110.000 ± 0.010 mm (4.3307 ± 0.0004 inch) 
(1) Stress plate needs to be installed to measure bore accurately

Note: Bore size must be checked with a 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines).

Note: Take the main measurements of the bearing bore after machining and before removing the bearing caps. Install the front camshaft bearing. Align the bearing oil hole with the oil hole in the block and the oil hole in the bearing joint.



Illustration 8g01691893
Right side view of a 3114 and 3116


Illustration 9g01696454
Right side view of a 3126

Table 5
Right Side Dimensions 
Callout  Models 3114 and 3116 Dimensions  3126 Dimension 
1.250 ± 0.250 mm (0.0492 ± 0.0098 inch)  1.250 ± 0.250 mm (0.0492 ± 0.0098 inch) 
14.000 ± 2.000 mm (0.5512 ± 0.0787 inch)  14.000 ± 2.000 mm (0.5512 ± 0.0787 inch) 
8.000 ± 0.050 mm (0.3150 ± 0.0020 inch)  N/A 
8.000 ± 0.050 mm (0.3150 ± 0.0020 inch)  N/A 
12.000 ± 0.500 mm (0.4724 ± 0.0197 inch)  12.000 ± 0.500 mm (0.4724 ± 0.0197 inch) 


Illustration 10g06338268
(J) Bores for all camshaft bearings except the front bearing
(10) Locate bearing oil hole for all camshaft bearings with the bore in the block

Table 6
Dimensions of the Rear Face 
Callout  Dimension 
69.00 ± 0.038 mm (2.716 ± 0.0015 inch) 

Main Bearing Cap Width

  1. Check the width of the guide for the main bearing cap.

  2. Replace main bearing caps that are less than the minimum width of 159.94 mm (6.297 inch).

  3. Install main bearing caps on a reconditioned engine, and use only new cap bolts and washers.

Line Boring the Cylinder Block

Tooling

Use 1P-4000 Line Boring Tool Group to perform the line bore. Refer to Special Instruction, SMHS7606, "Using 1P-4000 Line Boring Tool Group" for a description of this tool.

Centering Rings

Standard centering rings and oversized centering rings must be purchased.

Changes to Boring Procedure

Refer to Special Instruction, SMHS7606, "Use of 1P-4000 Line Boring Tool Group".

Place the 4C-9765 Centering Rings with the oiler on each side of the cap that is being replaced. For an end cap, place 4C-9765 Centering Rings in the second and fourth main bearing bores on four cylinder engines and in the second and fifth bearing bores on six cylinder engines.



Illustration 11g01700318
(11) 4C-9765 Centering Rings
(12) Oiler

Tighten the bolts on the bearing caps with centering rings 27.0 N·m (19.91 lb ft) to 70.0 N·m (51.62 lb ft). All other bearing cap bolts should be tightened to the specifications in the service manual.

Place the tool bit in the holder and set the micrometer 1.78 mm (0.070 inch) less than the finished bore diameter. The finished bore diameter is 95.000 ± 0.013 mm (3.7402 ± 0.0005 inch). Verify that this dimension before bearing caps are removed.



Illustration 12g01701117
(13) Original bearing caps
(14) Bolts
(15) New machined cap

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.



Illustration 13g03412760

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



Illustration 14g01701617
(K) Height of the Block
(16) Identification of resurfaced block
(17) crankshaft bore

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

If the block requires resurfacing, use the specifications in Table 6. These specifications are independent from the amount of material that is removed from the cylinder head. This material has separate specifications. If the block is machined between 321.75 mm (12.667 inch) and 321.50 mm (12.657 inch) an identification mark must be stamped on the block. The identification mark is usually “TG”. This is shown in Illustration 15.



Illustration 15g01703517
(18) “TG” Marking

Table 7
Dimensions for Height of the Top Deck of the Block 
Description  Dimension 
Flatness of the Surface  0.05 mm (0.002 inch) for any 150.00 mm (5.906 inch) span 
New height of the block(1)  322.000 ± 0.017 mm (12.6771 ± 0.0007 inch) 
Minimum height of the block with a standard head gasket(1)  321.750 mm (12.6673 inch) 
Absolute minimum height with a special head gasket(1)  321.500 mm (12.6575 inch) 
(1) Measured from the centerline of the main bearing bore

Engine blocks with heights less than 321.75 mm (12.667 inch) require the use of special head gaskets. The part numbers of these special head gaskets are 4P-2591 Cylinder Head Gasket, 4P-2590 Cylinder Head Gasket, and 119-2948 Cylinder Head Gasket. These gaskets are 0.25 mm (0.010 inch) thicker than the standard head gaskets.

The thicker head gaskets allow the top deck of the block to be resurfaced to lower dimensions that would be unacceptable with the standard head gasket. The increased material that is removed from the deck of the block causes the pistons to project higher above the surface of the block during travel. The thicker head gasket keeps the pistons from contacting the cylinder head and the valves.

If the block is resurfaced, the block should be identified on the left side in the middle of the block. Refer to Illustration 14 and Illustration 15.

Note: The thicker head gaskets should not be used unless the block has been resurfaced below the minimum specified measurement. A gasket that is too thick will cause a low compression ratio. Gaskets that are too thick may also cause hard starting and excessive white smoke.

Installation of Stress Plate

Note: The stress plate is only used when measuring the bores and when hard honing. It is NOT to be used when boring the cylinders.

If the dimensions of a cylinder, or cylinders, is to be accurately measured with a 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines) and a STANDARD thickness cylinder head gasket must be installed over each cylinder that is to be measured.

Table 8
Stress Plate Part Numbers 
Engine  Stress Plate  Stress Plate Group 
3114 / 3116  4C-4377  126-8132 
3126  142-2285  125-2064 

The correct installation of the STANDARD thickness cylinder head gasket, stress plate group or cylinder head stress plate, and cylinder head bolts will cause the cylinder bore to distort and have the same dimensions that it would have if the cylinder head was installed and properly tightened. Refer to Table 8 for stress plate group or cylinder head stress plate part numbers.

The gasket and stress plate must be installed to accurately measure the cylinder sleeve. If a stress plate group is used, it must be installed over each cylinder



Illustration 16g06337899
Cylinder head stress plate (1).


Illustration 17g06337900
Cylinder head stress plate (1) installed on block (5) with STANDARD gasket (4) using bolts (2) and washers (3).

  1. Install a STANDARD thickness cylinder head gasket (4) on cylinder block (5).

    Note: The head surface of the cylinder should contain dowels to position cylinder head gasket (4).

  2. Position stress plate (1) over cylinder head gasket (4).

  3. Install (original) cylinder head bolts (2) through the stress plate into cylinder block.

  4. Initially tighten all bolts (2) evenly to 150 ± 15 N·m (110 ± 11 lb ft).

  5. Finish tightening all bolts (2) evenly to 435 ± 20 N·m (320 ± 15 lb ft).

Measuring and Cleaning Cylinder Bores

Measuring the Cylinder Bores



Illustration 18g01402413
1P-3537 Dial Bore Gauge Group


Illustration 19g06238831

Measure the cylinder bore parallel to the crankshaft. Measure the cylinder bore at a right angle to the crankshaft. Measure the cylinder bore at the top, the middle, and the bottom. The areas of the cylinder bore that receives the most wear is at the top and the bottom of ring travel.

Be sure that the gauge pin has sufficient travel to measure the points of maximum wear in the bore. In a cylinder bore, the maximum wear is usually across the diameter that is perpendicular to the centerline of the crankshaft, either at the top or the bottom of ring travel.

Use the 1P-3537 Dial Bore Gauge for the actual measurement. This group includes a 1P-3535 Dial Bore Gauge and a 1P-3536 Size Setting Fixture. Special Instruction, GMG00981, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size".

Measure all cylinder bores with the 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines) and a STANDARD thickness cylinder head gasket must be installed over each cylinder that is to be measured.

Cleaning the Cylinder Bores



Illustration 20g06338340
Typical example of a nylon brush that is used to clean the cylinder bores

Use a nylon brush to clean the cylinder bores. Clean the cylinder bores before measuring to ensure an accurate measurement. Refer to Table 9 for the part numbers of the nylon brushes.

Table 9
Sales Model  Brush 
3114, 3116,3126  1U-7429 

Honing Parent Cylinder Bores

Make sure that the following preliminary check is made to determine if honing is necessary. Determine if honing is necessary, and if the bore's size allows honing. If the bore measures less than the maximum diameter, honing is possible. If the bore measures more than the maximum diameter, a sleeve must be installed.

The bore size determines the necessity of honing the bores or installing sleeves. Refer to Table 10 for honing limits.

Table 10
Honing Dimensions for the Cylinder 
Description  3114 and 3116  3126 
New cylinder bore diameter  105.025 ± 0.025 mm (4.1348 ± 0.0010 inch)  110.025 + 0.025 - 0.010 mm (4.3317 + 0.0010 - 0.00039 inch) 
Limitations of the Flexible Hone  105.000 mm (4.1338 inch) to 105.130 mm (4.1390 inch)  110.000 mm (4.3307 inch) to 110.130 mm (4.3358 inch) 
Limitations of the Rigid Hone  105.131 mm (4.1390 inch) to 105.229 mm (4.1429 inch)  110.131 mm (4.3359 inch) to 110.229 mm (4.3397 inch) 

Cylinder bores which have at least 75% of crosshatch scratch pattern and only light vertical scratches can be restored by flexible honing of the cylinder bores.

Cylinder bores with less than 75% of the original pattern of the crosshatch should be reconditioned.

3114 and 3116 bores that are larger than 105.229 mm (4.1429 inch) require a 7C-6208 Cylinder Sleeve.

3126 bores that are larger than 110.229 mm (4.3397 inch) require a 107-7604 Cylinder Sleeve.

Note: Honing is not recommended on any engine that is restricted by emissions.

If honing is performed on an engine that is not restricted by emissions, oil consumption, wear, and blow by should be considered.

Cylinder reconditioning with flexible hones establishes cylinder wall finish and provides good oil control if done correctly, it also good for deglazing the walls of cylinders that are not out-of-round. The 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines) is not used when the flexible honing operation is performed.



Illustration 21g01687075
(A) 6.40 mm (0.25197 inch) from each end of the cylinder bore
(B) Center measurement location.

When using rigid bar honing, check the bore size at several locations. Be sure to check locations over the length of the bore and around the circumference. Measure the points that are perpendicular to the centerline of the crankshaft. These points are located (A) 6.40 mm (0.25197 inch) from each end and at the center of the bore. These specific locations are primary gauge positions during honing. Use the 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines) during rigid bar honing.



    Illustration 22g03682143
    Flexible hone use to condition the cylinder bores prior to piston installation.

  1. Use a flexible hone that has 240 grit abrasive on the tips. Caterpillar provides a 1U-7428 Flexible Hone (Flex-Hone), used for 3114 and 3116 Engines and 4C-6336 Flexible Hone (Flex-Hone) used for 3126 Engines.

  2. Apply a light solvent or kerosene for lubrication. Do not use engine lubricating oil.

  3. While operating the hone, move up and down the liner at a rate of approximately 30 strokes per minutes, one stroke being one complete cycle up and down. (This rate would be one second down and one second up).

  4. Vary the stroke rate as necessary to achieve the correct crosshatch angle (140±10°). If the crosshatch is much less than 140°, decrease the number of strokes per minute or increase the rpm of the drill. If the pattern is too flat (greater than 140°), increase the number of strokes per minute or decrease the speed of the drill.

A new flexible hone should restore the surface in approximately 30 seconds. Flexible hone that is worn out will not cut deep enough and the surface will be too smooth and shiny. An adjacent cylinder can be used as a reference for the correct crosshatch pattern.

Installing a 7C-6208 Cylinder Sleeve for 3114 and 3116 Engines and 107–7604 Cylinder Sleeve for 3126 Engines

The 7C-6208 Cylinder Sleeve is available for reconditioning the cylinder blocks used in 3114 and 3116 Engines. The 107-7604 Cylinder Sleeve is available for 3126 Engines. Use the cylinder sleeves when it is determined that the existing cylinder wall(s) are not reusable because of wear, pin holes, cracks, or scoring.

Inspect the cylinder block carefully to be sure it is still usable. If sleeves are to be installed, use the procedure given in this Guideline.

If the dimension of a cylinder, or cylinders, is to be accurately measured, a 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines) and a STANDARD thickness cylinder head gasket must be installed over each cylinder that is to be measured.

Measuring Wall Thickness for 3126 Engines



    Illustration 23g01360197
    93028 Digital Disc Brake Caliper


    Illustration 24g01360198
    Measuring cylinder bore wall thickness with 93028 Digital Disc Brake Caliper

  1. Use the 93028 Digital Disc Brake Caliper to measure the wall thickness at the front of each cylinder 30.0 mm (1.18110 inch) below the top face of the block. Measure the block by putting the thin leg of the caliper through the water passage between the cylinders. If the minimum wall thickness on any cylinder is less than 4.3 mm (0.16929 inch), replace the block.

  2. If the cylinder block passes Step 1, follow the procedure to install a sleeves in the bores that are not within factory specifications.

Machining Procedure



Illustration 25g06337863
Machining specifications for bore in block.

Note: The stress plate group or the cylinder head stress plate is ONLY used when measuring the bores or performing the honing procedure. The stress plate is not used during block boring procedure. Refer to Table 8 for stress plate group or cylinder head stress plate part numbers.

Table 11
Bore in Block Machining Dimensions 
Callout  7C-6208 Cylinder Sleeve (3114/3116)  107-7604 Cylinder Sleeve (3126) 
(A)  Original Cylinder Bore Diameter  Original Cylinder Bore Diameter 
(B)  109.732 ± 0.013 mm (4.32015 ± 0.00051 inch)  114.775 ± 0.013 mm (4.51869 ± 0.00051 inch) 
(C)  196.77 ± 1.13 mm (7.74683 ± 0.04449 inch)  196.85 ± 0.08 mm (7.74998 ± 0.00315 inch) 
(D)  0.3 mm (0.01181 inch) X 45 degree radius  0.3 mm (0.01181 inch) X 45 degree radius 
(E)  0.5 mm (0.01969 inch) X 45 degree chamfer  0.5 mm (0.01969 inch) X 45 degree chamfer 

Position boring tool on cylinder block.

Note: Dimension (A) is the diameter of the original bore.

  1. Use the centerline of the original cylinder bore (A), and machine the bore to diameter (B) and depth (C). The new bore must be within 0.5 mm (0.01969 inch) total runout with the centerline of original cylinder bore (A).

    Note: Dimension (C) is measured from the top deck (top surface) of the cylinder block.

  2. Remove the sharp corner and any burrs at the bottom edge of bore (B).

Installation of Cylinder Sleeve



Illustration 26g06337871
Cylinder sleeve installation tooling.

Table 12
Item Identification 
Callout  Description  Part Number 
3114 / 3116 3126
(1)  Forcing Screw  6V-2183 
(2)  Insert  1P-2329 
(3)  Hydraulic Puller Group  1P-0820 
(4)  Puller Plate  9U-6008  129-9197 
(5)  Cylinder Sleeve  7C-6208  107-7604 
(6)  Puller Plate  9U-6007  129-9196 
(7)  Nut  1D-5119 
(8)  Adjusting Crank  9S-6072 
(9)  Washer  5H-1504 

  1. Remove the 9S-6074 Adjusting Screw from hydraulic puller group (3) and install forcing screw (1) in its place.

  2. Use hydraulic puller group (3) with forcing screw (1), insert (2), puller plate (4), puller plate (6), washer (9), nut (7), and cylinder sleeve (5) as shown in Illustration 26.

    Note: Install the cylinder sleeve (5) with the 10º outside diameter chamfer toward the cylinder block.

  3. Put clean diesel fuel (No. 2) on the outside diameter of cylinder sleeve (5).

  4. Connect a hydraulic pump to hydraulic puller group (3) and pull cylinder sleeve into the bore.

  5. Reposition the hydraulic puller group.

    1. Retract hydraulic puller group (3).

    2. Loosen the socket head screw and readjust insert (2).

    Note: Insert (2) will need to be readjusted several times before the sleeve is fully installed.



    Illustration 27g06337875
    Cylinder sleeve (5) is installed and has complete contact (10) with bottom of bore.

  6. Pull cylinder sleeve (5) into the bore until the bottom of the sleeve contacts the counterbore at location (10).


    Illustration 28g06337879
    (5) Cylinder Sleeve
    (H) Maximum of 0.013 mm (0.00051 inch) above the top deck of the block


    NOTICE

    If the top of the cylinder sleeve is machined, do NOT nick or cause damage to the top deck of the cylinder block. To ensure a correct seal between the bottom of the cylinder head and the top surface of the cylinder block near the cylinder sleeve, the cylinder head gasket MUST have a smooth surface to seal against.


  7. After cylinder sleeve (5) is installed in the cylinder bore, it is acceptable for the top of the cylinder sleeve to extend a maximum of 0.013 mm (0.00051 inch), above the cylinder block top deck. For best installation results, the cylinder sleeve should be flush with the top deck of the cylinder block.

    Note: It is acceptable to machine the top of the cylinder sleeve, so it is even with the cylinder block top deck.



    Illustration 29g06391501
    Machine chamfer (I) on the top of cylinder sleeve (5).

  8. Machine a chamfer after the sleeve is inserted into the bore. See Illustration 29 and Table 13.

    Table 13
    Specifications for Cylinder Sleeves 
    Callout  3114/3116  3126 
    4.0 mm (0.15748 inch) MAX 
    1.02 ± 0.25 mm (0.04016 ± 0.00984 inch) 
    Blend from chamfer (K) to the bore of the sleeve by using a flex-hone. 
    30° 
    Maximum of 0.013 mm (0.00051 inch) above the top deck of the block 

  9. Use the 1P-3565 Chamfering Group to remove the sharp corner at the bottom of each cylinder bore. The chamfer must be approximately 2.3 mm (0.09055 inch) x 15 degrees. The chamfer is necessary to prevent scuffing of the piston skirt.

Stress Honing Procedure

Installation of Stress Plate

If the dimensions of a cylinder, or cylinders, is to be accurately hone with a 4C-4377 or 126-8132 Cylinder Head Stress Plate for (3114/ 3116 Engines) or 125-2064 or 142-2285 Cylinder Head Stress Plate for (3126 Engines) and a STANDARD thickness cylinder head gasket must be installed over each cylinder that is to be honed.

Table 14
Stress Plate Part Numbers 
Engine  Stress Plate  Stress Plate Group 
3114 / 3116  4C-4377  126-8132 
3126  142-2285  125-2064 

The correct installation of the STANDARD thickness cylinder head gasket, stress plate group or cylinder head stress plate, and cylinder head bolts will cause the cylinder bore to distort and have the same dimensions that it would have if the cylinder head was installed and properly tightened. Refer to Table 8 for stress plate group or cylinder head stress plate part numbers.

The gasket and stress plate must be installed to accurately measure the cylinder sleeve. If a stress plate group is used, it must be installed over each cylinder



Illustration 30g06337899
Cylinder head stress plate (1).


Illustration 31g06337900
Cylinder head stress plate (1) installed on block (5) with STANDARD gasket (4) using bolts (2) and washers (3).

  1. Install a STANDARD thickness cylinder head gasket (4) on cylinder block (5).

    Note: The head surface of the cylinder should contain dowels to position cylinder head gasket (4).

  2. Position stress plate (1) over cylinder head gasket (4).

  3. Install (original) cylinder head bolts (2) through the stress plate into cylinder block.

  4. Initially tighten all bolts (2) evenly to 150 ± 15 N·m (110 ± 11 lb ft).

  5. Finish tightening all bolts (2) evenly to 435 ± 20 N·m (320 ± 15 lb ft).

Honing Procedure

Finished bore dimension measurements must be made with the stress plate installed. The stress plate is to make sure that the correct cylinder dimensions are maintained after the cylinder head is installed.

Table 15
Rottler HP3A Honing Machine Data
Make sure that the stress plate is installed prior to any machining procedures on the cylinder sleeve. 
Item  Rough (1)  Semi-Finish  Finish 
3114/3116 3126  3114/3116  3126  3114/3116  3126 
Standard Bore  104.935 ± 0.025 mm (4.13129 ± 0.00098 inch)  109.935 ± 0.025 mm (4.32814 ± 0.00098 inch)  104.986 ± 0.025 mm (4.13330 ± 0.00098 inch)  109.986 ± 0.025 mm (4.33015 ± 0.00098 inch)  105.025 ± 0.025 mm (4.13483 ± 0.00098 inch)  110.025 + 0.025 - 0.010 mm (4.3317 + 0.0010 - 0.00039 inch) 
Cylinder Length  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch) 
Hone Head  514-5-61B  514-5-61B  514-5-61B 
Stroke Scale  15.9 mm (0.62598 inch)  15.9 mm (0.62598 inch)  15.9 mm (0.62598 inch) 
Cylinder Length Setting  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch) 
Rotation Speed (rpm)  165  165  165 
Strokes per Minute  55  55  55 
Feed Rate  0.0102 mm (0.00040 inch) per 2 strokes  0.0102 mm (0.00040 inch) per 5 strokes  0.0102 mm (0.00040 inch) per 7 strokes 
Top Over Stroke  19.05 mm (0.75000 inch)  19.05 mm (0.75000 inch)  19.05 mm (0.75000 inch) 
Stone  514–5–54M (80 grit)  514–5–54N (180 grit)  514–5–54Q (320 grit) 
Load Meter  100%  80%  40% 
Stock Removal Rate per Minute  0.076 to 0.102 mm (0.00299 to 0.00402 inch)  0.051 mm (0.00201 inch)  0.020 mm (0.00079 inch) 
Honing per Each 0.03 mm (0.00118 inch) Stock Removal, Advance Feed  3 increments  3 increments  2 increments 
Surface Texture  2.3 to 3.05 µm (90.55118 to 120.0787 µinch)  0.64 to 0.99 µm (2519685 to 38.97638 µinch)  0.31 to 0.50 µm (12.20472 to 19.68504 µinch) 
(1) Rottler recommends boring (cutting) for the cylinder sleeve rough cut, rather than honing. Both methods are acceptable.

Table 16
Sunnen Honing Machine Data
Make sure that the stress plate is installed prior to any machining procedures on the cylinder sleeve. 
Item  Rough  Semi-Finish  Finish 
3114/3116 3126  3114/3116  3126  3114/3116  3126 
Standard Bore  104.935 ± 0.025 mm (4.13129 ± 0.00098 inch)  109.935 ± 0.025 mm (4.32814 ± 0.00098 inch)  104.986 ± 0.025 mm (4.13330 ± 0.00098 inch)  109.986 ± 0.025 mm (4.33015 ± 0.00098 inch)  105.025 ± 0.025 mm (4.13483 ± 0.00098 inch)  110.025 + 0.025 - 0.010 mm (4.3317 + 0.0010 - 0.00039 inch) 
Cylinder Length  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch) 
Hone Head  CK–3000  CK–3000  CK–3000 
Stroke Scale  69.9 mm (2.75196 inch)  69.9 mm (2.75196 inch)  69.9 mm (2.75196 inch) 
Cylinder Length Setting  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch)  203.2 mm (7.99998 inch) 
Cylinder Length Setting  152.0 mm (5.98424 inch)  152.0 mm (5.98424 inch)  152.0 mm (5.98424 inch) 
Rotation Speed (rpm)  155 (1)  155 (1)  155 (1) 
170 (2) 170 (2)  170 (2) 
Strokes per Minute  46 (1)  46 (1)  46 (1) 
57 (2) 57 (2)  57 (2) 
Feed Rate 
Top Over Stroke  9.5 mm (0.37402 inch)  9.5 mm (0.37402 inch)  9.5 mm (0.37402 inch) 
Stone  EHU - 123  EHU - 525  EHU - 625 
Load Meter  85%  75%  40% 
Stock Removal Rate per Minute  0.13 mm (0.00512 inch)  0.064 mm (0.00252 inch)  0.051 to 0.064 mm (0.00201 to 0.00252 inch) 
Honing per Each 0.03 mm (0.00118 inch) Stock Removal, Advance Feed  0.03 mm (0.00118 inch)  0.08 mm (0.00315 inch)  0.08 mm (0.00315 inch) 
Surface Texture  N/A  N/A  0.20 to 0.50 µm (7.874016 to 19.68504 µinch) 
(1) For a Sunnen CK-10 Honing Machine.
(2) For a Sunnen CV-616 Honing Machine.

  1. After the stress plate group is correctly installed (as shown in Illustration 17) proceed with the honing operation.

    Note: For the correct honing specifications, use Table 15 or Table 16, depending on the honing/boring machine being used.



    Illustration 32g06337902
    Cross hatch pattern and finished bore diameter.
    (7) Cross hatch pattern
    (I) 140 ± 10 degrees
    (J) 3114 and 3116 Engines: 105.025 ± 0.025 mm (4.13483 ± 0.00098 inch). 3126 Engines: 110.025 + 0.025 - 0.010 mm (4.3317 + 0.0010 - 0.00039 inch).


    Illustration 33g06337905
    Magnified view of cross hatch pattern (7).
    (K) Surface (land) area
    (L) Honing scratch or groove

  2. Hone the sleeve to obtain a cross hatch pattern (7), Illustration 32) with an angle of 140 ±10 degrees (I), Illustration 32). The cross hatch scratch pattern must be the same in both directions.

    Honing grooves (L), Illustration 33) must be 0.025 to 0.050 mm (0.00098 to 0.00197 inch) deep, and surface (K), Illustration 33) must be 40 to 65% of the surface.

    The scratch pattern must also be free of any material that can bend over and close the open area of honing grooves (L).

  3. The honed surface must be free of glaze and/or burnish. Refer to the"Glaze"and "Burnish" sections for additional information.


    Illustration 34g06337912
    Use a dial bore indicator and check the diameter of the bore.

  4. During honing, check the size of the bore at several locations along the length of the bore and also around the circumference.


    Illustration 35g06337915
    Check the bore diameter at locations (M) and (N). Location (M) is 6.4 mm (0.25197 inch) (O) from each end of the sleeve.

  5. Inspect the bore dimension at several points that are perpendicular (at right angles) to the crankshaft centerline. The following three specific locations are primary gauge points, both during and after honing.

    1. Check the diameter at locations (M), Illustration 35), 6.4 mm (0.25197 inch), from each end of the sleeve.

    2. Check the diameter at the center of the sleeve, location (N), Illustration 35.

  6. After the honing cycle is completed and before the engine is assembled, remove the camshaft bearings to permit cleaning of the cylinder block.

Glaze

Glazing produces a brown color on the surface of the cylinder wall.

Glazing can be caused by honing stones that are not cutting correctly or honing stones which are overheating. Overheating causes the honing oil to oxidize and transfer the residue into the cylinder wall.

Inspect the tooling to make sure that the honing stones are seated correctly in the holders. The honing stones must also be used with the recommended volume and type of honing oil.

Make sure the recommended Stock Removal Rate, Honing Per 0.03 mm (0.00118 inch) Stock Removal, and Advance Feed settings are correct for the tooling being used. Refer to Table 11 and 8.

Burnish

Burnish is when the cylinder walls have a smooth finish or shiny surface, but there are areas of the bore that have not been honed correctly.

Burnishing can be caused by honing stones that are not in even contact with the cylinder wall.

Inspect to make sure that the honing stones are seated correctly in the holders. Check for even wear of the honing stones and make sure that the tooling is correctly aligned.

Cleaning the Cylinder Bore

After the honing procedure is completed and before the engine is assembled, remove the camshaft bearings and clean the cylinder block.


NOTICE

The result of incomplete and/or insufficient cleaning of the cylinder block will be piston seizure or rapid wear of the cylinder sleeve bores, pistons and piston rings.

Only the thorough use of a rotary brush will correctly remove the abrasive particles left behind from the honing procedure.


Use a 1P-5580 Brush with a strong detergent and water solution to thoroughly clean the cylinder block, the main oil gallery and oil supply passage, the camshaft bearing oil passages, and the cylinder bores.

The cylinder block must be thoroughly cleaned in an agitator-type cleaning tank.



Illustration 36g06338340
1U-7429 Nylon Brush is used to clean the cylinder bores after honing.

Note: Use the 1U-7429 Nylon Brush to clean the honed bore of the cylinder sleeve. Put clean SAE 30W engine oil on all machined surfaces after the cleaning procedure is completed.

Keep a protective cover on the cylinder block until final assembly.

3116 Block Head Bolt Hole Salvage

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.

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 3116 Blocks.

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 a rebuild, most cracks are found in threaded holes. 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.

Crack Detection Methods

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

Check the top deck of the block for cracks. Use the 263-7184 Crack Detection Kit to detect cracks. 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.


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), and Magnetic Particle Inspection (MT) 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. Refer to Table 17 for advantages and disadvantages and Table 18 for standards and requirements for these NDT methods.

Table 17
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 inch 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 

Table 18
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 

Visual Surface Inspection (VT)

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. It is suggested that at a minimum personnel performing Visual Inspection are either trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. It is also suggested that personnel performing visual inspections take some type of eyesight test regularly.

Liquid Penetrant Testing (PT)

------ WARNING! ------

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

  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.

  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.

  3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.

  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.

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

  6. Check the surface with a 459-0184 Ultraviolet Lamp. This lamp will highlight the location of any cracks or damage.

Dry Magnetic Particle Testing (MT)

Refer to Tooling and Equipment Table 3 for part numbers.



Illustration 37g06085930
(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)

Refer to Tooling and Equipment Table 3 for part numbers.



Illustration 38g06085937
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke.
(D) UV Lamp used in wet magnetic particle inspection process.


Illustration 39g06003178
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 39. 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. An AC yoke shall be used.

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

  5. Record the size and shape of any discontinuities found.

Procedure



    Illustration 40g06338275

  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.


    Illustration 41g06338278


    Illustration 42g06338283

  2. Center the drill over the hole.

  3. Clamp the drill into position.


    Illustration 43g06338284

  4. Use the 57/64 inch drill. Use a stop collar to set the depth of the drill to a depth of 77.62 mm (3.056 inch). Be sure that the collar on the drill bit touches the top deck of the block when you drill the hole.

  5. Remove the drill bit.


    Illustration 44g06338289

  6. Remove all metal shavings from the hole.


    Illustration 45g06338290

  7. Tap the hole with the roughing tap (20 mm Thread). Apply tapping fluid to the tap while you are tapping.


    Illustration 46g06338293

  8. Remove all metal shavings from the hole.


    Illustration 47g06338299

  9. Tap the hole with the finishing tap (20 mm Thread). Apply tapping fluid to the tap while you are tapping.

  10. Remove all metal shavings from the hole.


    Illustration 48g06338302


    Illustration 49g06338304

  11. Remove the burrs from the hole with a file.


    Illustration 50g06338307

  12. Tap the hole again with the finishing tap (20 mm Thread) by using your hands.

    Note: The finishing tap must bottom in the hole.



    Illustration 51g06338311


    Illustration 52g06338316

  13. Clean the hole and the insert to remove all the oil and the metal shavings.


    Illustration 53g06338322

  14. Apply a liberal amount of sealant to the insert and the hole.


    Illustration 54g06338324

  15. Install the threaded insert (M20 thread) by using the Insert Installation Tool (20 mm Thread).

    Note: See the instructions in Full Torque Thread Insert Kit (M20 Thread) for instructions on assembling the Insert Installation Tool (20 mm Thread).



    Illustration 55g06338327

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


    Illustration 56g06338331

  17. Remove the Insert Installation Tool (20 mm Thread).


    Illustration 57g06338334


    Illustration 58g06338335

  18. Clean the hole and the surface.

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 19
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 20
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


NOTICE

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


Table 21
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 


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 22
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 59g06370992

Part Description

Table 23
Base Metal  Cast Iron 
Hardness  N/A 

Arc Spray Equipment and Procedure

Table 24
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 25
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 26
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 27
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   

Thermal Spray Procedures for Main Bearing Cap



Illustration 60g03513357
This is an example of a standard bearing cap. (A) is the bore dimension of the bearing cap, (B) is the width of the bearing cap, and (C) is the height of the bearing cap.


Illustration 61g03334317
This is an example of a V bearing cap. (A) is the bore dimension of the bearing cap, (B) is the width of the bearing cap, and (C) is the height of the bearing cap.

Table 28
Main Bearing Cap Specifications 
Engine Model  Dimension A  Dimension B  Dimension C 
3114  92.2 ± 0.4 mm (3.62991 ± 0.01575 inch)  159.995 ± 0.02 mm (6.29900 ± 0.00079 inch)  88.0 ± 0.5 mm (3.46456 ± 0.01969 inch) 
3116, 3126, 3126B  95.000 ± 0.013 mm (3.7401 ± 0.0005 inch)  159.995 ± 0.025 mm (6.2990 ± 0.0010 inch)  88.000 ± 0.500 mm (3.4646 ± 0.0200 inch) 

Part Description

Table 29
Base Metal  Hardness 
Cast Iron  28 - 34 Rc 

Arc Spray Equipment and Procedure

Table 30
Maximum Surface Texture  1.6 µm (62.99213 µinch) 
Reason for Spraying  Wear and/or bearing failure 
Mating Part Contact Area & Material  Bearing sleeve and press fit 
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° C (150° F) Do not direct arc on area to be sprayed 
Substrate Temperature During Spraying Not to Exceed  148° C (300° F) 
Auxiliary Cooling  Filtered shop air 
Rotation/Traverse Device  Lathe or headstock/tailstock arrangement, rotary turntable 
Rotation/Traverse Speed  11 SMPM (36.00 SFPM) 
Surface Preparation Method  Undercut and grit blast 
Machining Method  Machine 
Equipment Required  Mill, Line boring machine 
Recommended Cutting Tool  ISCAR DNMG 432 TFIC507 
Blast Media Recommendation  Pressure Type Only (Aluminum Oxide Grit) 
Remarks  Badly discolored caps (heavily burned due to bad bearing failure) should not be rebuilt 

Table 31
Arc Spray  Procedure  Check List 
Clean Part  Degrease in hot caustic solution   
Undercut  Not required   
Chamfer  All edges - 45° x .76 mm (.030 inch)   
Remove Oxide  Emery paper or glass beading (mating face), Flapper wheel - 60 grit (bearing sleeve)   
Mask for Grit Blast  Metal mask type only   
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 to 150 mm (2.0 to 6.0 inch)   
Remove Blast Mask  Make sure that surface is clean   
Mask for Metal Spray  Use metal mask or METCO Anti-bond   
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) per pass  0.038 mm (0.0015 inch) per 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  0.058 mm (0.00228 inch) per pass  0.058 mm (0.00228 inch) per pass   
  Rotation Speed of Part (RPM)  RPM varies depending on diameter   
  Rotation Speed of Part  92 SMPM (300.00 SFPM)   
  Traverse Rate of Gun  11 SMPM (36.00 SFPM)   
Gun Fixturing Method  Machine mounted or hand held   
Finishing Equipment  Milling machine, line boring machine   
Part/Cutter Rotation (Roughing)  50 SMPM (150 SFPM)   
Part/Cutter Rotation (Finishing)  75 SMPM (250 SFPM)   
Coolant  Oil based synthetic - 40:1 ratio   
Traverse Cut  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 32
Maximum Surface Texture  1.6 µm (62.99213 µinch) 
Reason for Spraying  Bearing failure 
Mating Part Contact Area & Material  Crankshaft main bearing sleeve 
Oerlikon Metco Equipment Type  6P-II by Oerlikon Metco 
Metco Material  Metco 453 
Finish Thickness  As required 
Finishing Allowance  0.51 mm (0.020 inch) per side 
Spray Angle  90° to bore 
Substrate Pre-Heat Temperature  66° C (150.8° F) Do not direct flame on area to be sprayed 
Substrate Temperature During Spraying Not to Exceed  148° C (298.4° F) 
Auxiliary Cooling  A J Unit 
Rotation/Traverse Device  Hand held 
Rotation/Traverse Speed  15 SMPM (50.00 SFPM) 
Surface Preparation Method  Grit Blast 
Finishing Method  Machine 
Machining Equipment Type  Line Boring Machine 
Recommended Cutter Grade  C-2, 883 Carboloy, or equivalent 
Remarks  Badly discolored caps (heavily burned due to bad bearing failure) should not be rebuilt 

Table 33
Flame Spray Process (6P-II)  Procedure  Check List 
Clean Part  Degrease in hot caustic solution   
Undercut  Not required   
Chamfer  All edges 45° x 0.76 mm (0.030 inch)   
Remove Oxide  Flapper wheel - 60 grit   
Mask for Grit Blast  Use metal mask or duct tape   
Grit Blast Equipment  Pressure or suction blast   
Grit Type and Size  24 mesh aluminum oxide   
Blast Air Pressure  690 kPa (100.0 psi)   
Blast Nozzle to Work Distance  51 to 150 mm (2.0 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  METCO A J Siphon Air Jet   
Nozzle  6P7-CK "K" Nozzle   
Air Capacity/Pressure  6P-3/Cooling Air 140 kPa (20.0 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)/hr or 90 gr (3.2 oz)/min   
Gun to Work Distance  230 mm (9.0 inch)   
Rotation Speed of Part  91.4 m (299.869 ft)   
Traverse Rate of Gun  15.24 m (50.0 ft)   
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  Standard   
Traverse Speed  Standard   
Depth of Rough Cut  0.25 to 0.51 mm (0.010 to 0.020 inch) per side   
Depth of Finish Cut  0.13 mm (0.005 inch) or less per side   
Additional Finish Method  Flex hone if necessary   

-Do not direct flame on area to be sprayed.

-Excessive heat will cause cap draw in.

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 62.

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 63.

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



Illustration 62g06278538
Example of protection for a component that is stored for a shorter term


Illustration 63g06278539
Example of protection for a component that is stored for a longer period
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