- Caterpillar Products
- All 3100 Engines
Introduction
Revision | Summary of Changes in SEBF8192 |
---|---|
10 | Added sleeve installation. |
9 | 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 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, 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.
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 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 |
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The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired. |
References
References | |
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Media Number | Title |
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.
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 |
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Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools. |
Required Tooling and Equipment | |
Part Number | Description |
Nut | |
Hydraulic Puller | |
Insert | |
Puller Plate | |
Gauge Body | |
Dial indicator | |
Dial Bore Gauge | |
Chamfering Tool | |
Line Boring Tool | |
Brush | |
Feeler Gauge | |
Flexible Hone | |
Brush | |
Gauge Block | |
Wrench | |
Cylinder Head Stress Plate (1) | |
Penetrant | |
Flexible Hone | |
Center Rings | |
Washer | |
Dial Bore Gauge | |
Wrench | |
Brush | |
Forcing Screw | |
Deck Checking Tool Assembly | |
Surface Plate | |
Wrench | |
Cylinder Sleeve | |
Thread Identification Kit | |
Adjusting Crank | |
Adjusting Screw | |
Cross Block | |
Puller Plate | |
Puller Plate | |
Puller Plate | |
Cylinder Sleeve | |
Cylinder Head Stress Plate (1) | |
Cylinder Head Stress Plate (1) | |
Puller Plate | |
Puller Plate | |
Cylinder Head Stress Plate (1) | |
Cleaner | |
Crack Detection Kit | |
Cylinder Head Stress Plate | |
UV Lamp Group | |
Degreaser | |
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
Refer to the Parts Manual for the correct STANDARD thickness cylinder head gasket.
Measurement Requirements
NOTICE |
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Precise measurements shall be made when the component and measurement equipment are at |
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.
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 |
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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 |
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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.
Flatness of the Top Deck
Illustration 4 | g06337213 |
(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
Main Bearing Bores
Illustration 5 | g06337217 |
(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
Camshaft Bore
Illustration 6 | g06337224 |
(5) Camshaft bearing |
Measure the camshaft bearing with a dial indicator.
Illustration 7 | g06338260 |
(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 |
Dimensions of the Front Face | ||
---|---|---|
Callout | Dimensions for 3114 and 3116 sales models | 3126 Dimension |
C | |
|
D (1) | |
|
E | |
|
F | |
|
G | |
|
H | |
(1) | Stress plate needs to be installed to measure bore accurately |
Note: Bore size must be checked with a
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 8 | g01691893 |
Right side view of a 3114 and 3116 |
Illustration 9 | g01696454 |
Right side view of a 3126 |
Right Side Dimensions | ||
---|---|---|
Callout | Models 3114 and 3116 Dimensions | 3126 Dimension |
5 | |
|
6 | |
|
7 | |
N/A |
8 | |
N/A |
9 | |
|
Illustration 10 | g06338268 |
(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 |
Dimensions of the Rear Face | |
---|---|
Callout | Dimension |
J | |
Main Bearing Cap Width
- Check the width of the guide for the main bearing cap.
- Replace main bearing caps that are less than the minimum width of
159.94 mm (6.297 inch) . - 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 11 | g01700318 |
(11) (12) Oiler |
Tighten the bolts on the bearing caps with centering rings
Place the tool bit in the holder and set the micrometer
Illustration 12 | g01701117 |
(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 13 | g03412760 |
6V-7840 Deck Checking Tool assembly includes the following tools. 4B-7640 Wrench, 7B-7640 Wrench, and 6B-7225 Wrenches
Illustration 14 | g01701617 |
(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
Illustration 15 | g01703517 |
(18) “TG” Marking |
Dimensions for Height of the Top Deck of the Block | |
---|---|
Description | Dimension |
Flatness of the Surface | |
New height of the block(1) | |
Minimum height of the block with a standard head gasket(1) | |
Absolute minimum height with a special head gasket(1) | |
(1) | Measured from the centerline of the main bearing bore |
Engine blocks with heights less than
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
Stress Plate Part Numbers | ||
---|---|---|
Engine | Stress Plate | Stress Plate Group |
3114 / 3116 | ||
3126 |
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 16 | g06337899 |
Cylinder head stress plate (1). |
Illustration 17 | g06337900 |
Cylinder head stress plate (1) installed on block (5) with STANDARD gasket (4) using bolts (2) and washers (3). |
- 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).
- Position stress plate (1) over cylinder head gasket (4).
- Install (original) cylinder head bolts (2) through the stress plate into cylinder block.
- Initially tighten all bolts (2) evenly to
150 ± 15 N·m (110 ± 11 lb ft) . - 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 18 | g01402413 |
|
Illustration 19 | g06238831 |
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
Cleaning the Cylinder Bores
Illustration 20 | g06338340 |
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.
Sales Model | Brush |
3114, 3116,3126 |
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.
Honing Dimensions for the Cylinder | ||
Description | 3114 and 3116 | 3126 |
New cylinder bore diameter | |
|
Limitations of the Flexible Hone | |
|
Limitations of the Rigid Hone | |
|
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
3126 bores that are larger than
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
Illustration 21 | g01687075 |
(A) (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)
- 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.
- Apply a light solvent or kerosene for lubrication. Do not use engine lubricating oil.
- 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).
- 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.
Illustration 22 | g03682143 |
Flexible hone use to condition the cylinder bores prior to piston installation. |
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
Measuring Wall Thickness for 3126 Engines
- 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 than4.3 mm (0.16929 inch) , replace the block. - If the cylinder block passes Step 1, follow the procedure to install a sleeves in the bores that are not within factory specifications.
Illustration 23 | g01360197 |
93028 Digital Disc Brake Caliper |
Illustration 24 | g01360198 |
Measuring cylinder bore wall thickness with 93028 Digital Disc Brake Caliper |
Machining Procedure
Illustration 25 | g06337863 |
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.
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) | |
|
(C) | |
|
(D) | |
|
(E) | |
|
Position boring tool on cylinder block.
Note: Dimension (A) is the diameter of the original bore.
- 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.
- Remove the sharp corner and any burrs at the bottom edge of bore (B).
Installation of Cylinder Sleeve
Illustration 26 | g06337871 |
Cylinder sleeve installation tooling. |
Item Identification | |||
---|---|---|---|
Callout | Description | Part Number | |
3114 / 3116 | 3126 | ||
(1) | Forcing Screw | ||
(2) | Insert | ||
(3) | Hydraulic Puller Group | ||
(4) | Puller Plate | ||
(5) | Cylinder Sleeve | ||
(6) | Puller Plate | ||
(7) | Nut | ||
(8) | Adjusting Crank | ||
(9) | Washer |
- Remove the 9S-6074 Adjusting Screw from hydraulic puller group (3) and install forcing screw (1) in its place.
- 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.
- Put clean diesel fuel (No. 2) on the outside diameter of cylinder sleeve (5).
- Connect a hydraulic pump to hydraulic puller group (3) and pull cylinder sleeve into the bore.
- Reposition the hydraulic puller group.
- Retract hydraulic puller group (3).
- 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.
Show/hide tableIllustration 27 g06337875 Cylinder sleeve (5) is installed and has complete contact (10) with bottom of bore. - Pull cylinder sleeve (5) into the bore until the bottom of the sleeve contacts the counterbore at location (10).
Show/hide table
Illustration 28 g06337879 (5) Cylinder Sleeve
(H) Maximum of0.013 mm (0.00051 inch) above the top deck of the blockShow/hide tableNOTICE 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.
- 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.
Show/hide tableIllustration 29 g06391501 Machine chamfer (I) on the top of cylinder sleeve (5). - Machine a chamfer after the sleeve is inserted into the bore. See Illustration 29 and Table 13.
Show/hide table
Table 13 Specifications for Cylinder Sleeves Callout 3114/3116 3126 G 4.0 mm (0.15748 inch) MAXI 1.02 ± 0.25 mm (0.04016 ± 0.00984 inch) J Blend from chamfer (K) to the bore of the sleeve by using a flex-hone. K 30° F Maximum of 0.013 mm (0.00051 inch) above the top deck of the block - 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.
Installation of Stress Plate
If the dimensions of a cylinder, or cylinders, is to be accurately hone with a
Stress Plate Part Numbers | ||
---|---|---|
Engine | Stress Plate | Stress Plate Group |
3114 / 3116 | ||
3126 |
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 30 | g06337899 |
Cylinder head stress plate (1). |
Illustration 31 | g06337900 |
Cylinder head stress plate (1) installed on block (5) with STANDARD gasket (4) using bolts (2) and washers (3). |
- 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).
- Position stress plate (1) over cylinder head gasket (4).
- Install (original) cylinder head bolts (2) through the stress plate into cylinder block.
- Initially tighten all bolts (2) evenly to
150 ± 15 N·m (110 ± 11 lb ft) . - 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.
Rottler HP3A Honing Machine Data
Make sure that the stress plate is installed prior to any machining procedures on the cylinder sleeve. |
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Item | Rough (1) | Semi-Finish | Finish | |||
3114/3116 | 3126 | 3114/3116 | 3126 | 3114/3116 | 3126 | |
Standard Bore | |
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Cylinder Length | |
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Hone Head | 514-5-61B | 514-5-61B | 514-5-61B | |||
Stroke Scale | |
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Cylinder Length Setting | |
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Rotation Speed (rpm) | 165 | 165 | 165 | |||
Strokes per Minute | 55 | 55 | 55 | |||
Feed Rate | |
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Top Over Stroke | |
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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 | |
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Honing per Each |
3 increments | 3 increments | 2 increments | |||
Surface Texture | |
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(1) | Rottler recommends boring (cutting) for the cylinder sleeve rough cut, rather than honing. Both methods are acceptable. |
Sunnen Honing Machine Data
Make sure that the stress plate is installed prior to any machining procedures on the cylinder sleeve. |
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Item | Rough | Semi-Finish | Finish | |||
3114/3116 | 3126 | 3114/3116 | 3126 | 3114/3116 | 3126 | |
Standard Bore | |
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Cylinder Length | |
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Hone Head | CK–3000 | CK–3000 | CK–3000 | |||
Stroke Scale | |
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Cylinder Length Setting | |
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Cylinder Length Setting | |
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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 | 6 | 6 | 4 | |||
Top Over Stroke | |
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Stone | EHU - 123 | EHU - 525 | EHU - 625 | |||
Load Meter | 85% | 75% | 40% | |||
Stock Removal Rate per Minute | |
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Honing per Each |
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Surface Texture | N/A | N/A | |
(1) | For a Sunnen CK-10 Honing Machine. |
(2) | For a Sunnen CV-616 Honing Machine. |
- 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.
Show/hide tableIllustration 32 g06337902 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) .Show/hide tableIllustration 33 g06337905 Magnified view of cross hatch pattern (7).
(K) Surface (land) area
(L) Honing scratch or groove - 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).
- The honed surface must be free of glaze and/or burnish. Refer to the"Glaze"and "Burnish" sections for additional information.
Show/hide table
Illustration 34 g06337912 Use a dial bore indicator and check the diameter of the bore. - During honing, check the size of the bore at several locations along the length of the bore and also around the circumference.
Show/hide table
Illustration 35 g06337915 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. - 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.
- Check the diameter at locations (M), Illustration 35),
6.4 mm (0.25197 inch) , from each end of the sleeve. - Check the diameter at the center of the sleeve, location (N), Illustration 35.
- Check the diameter at locations (M), Illustration 35),
- 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
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 36 | g06338340 |
|
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
NOTICE |
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Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings. |
Crack detection methods or Non-Destructive Testing (NDT) are utilized for examining components for cracks without damaging the component. Visual inspection (VT), Liquid Penetrant Testing (PT), 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.
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 |
- Requires Power for Light - Works on magnetic parts only - Liquid composition and agitation must be monitored |
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)
Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals. |
Materials and Equipment Required
Refer to Tooling and Equipment Table 3 for part numbers.
- Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.
- Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.
- Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrant indications.
- Wire Brush: Removes dirt and paint.
- Cloth or Wipes: Use with cleaner and for other miscellaneous uses.
Procedure
- Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry.
- 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.
- The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
- 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. - 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.
- 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 37 | g06085930 |
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke. (C) Dry powder bulb. |
- Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.
- Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.
- Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.
- Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least
4.5 kg (10 lbs) . - Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.
- All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.
Procedure
- Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.
- Apply the magnetic field using the yoke against the faces and inside diameter of each bore.
- Simultaneously apply the dry powder using the dry powder blower.
- Remove excess powder by lightly blowing away the dry particles.
- Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.
- Observe particles and note if any clusters of particles appear revealing an indication.
- Record the size and shape of any discontinuities or indications found.
Wet Magnetic Particle Testing (MT)
Refer to Tooling and Equipment Table 3 for part numbers.
Illustration 38 | g06085937 |
(A) Indications shown by magnetic particle testing.
(B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process. |
Illustration 39 | g06003178 |
Pear Shaped Centrifuge Tube |
- Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.
- Concentration:
- The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.
- Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a
1 mL (0.034 oz) stem with0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 39. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between0.1 mL (0.0034 oz) and0.25 mL (0.0085 oz) in a100 mL (3.40 oz) sample. - Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
- The oil shall have the following characteristics:
- Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.
- Low inherent fluorescence and be non-reactive.
- The conditioning agents used in the conditioned water shall have the following characteristics:
- Impart good wetting characteristics and good dispersion.
- Minimize foaming and be non-corrosive.
- Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at
38° C (100° F) . - Non-fluorescent, non-reactive, and odorless.
- Alkalinity shall not exceed a pH of 10.5.
- Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least
4.5 kg (10 lbs) .
Procedure
- Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.
- Apply the magnetic field using the yoke against the surface in the area to be inspected.
- For case hardened and ground surfaces:
- Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used.
- Visually inspect for indications of discontinuities using the proper illumination.
- Record the size and shape of any discontinuities found.
Procedure
- 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.
Show/hide table
Illustration 41 g06338278 Show/hide tableIllustration 42 g06338283 - Center the drill over the hole.
- Clamp the drill into position.
Show/hide table
Illustration 43 g06338284 - 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. - Remove the drill bit.
Show/hide table
Illustration 44 g06338289 - Remove all metal shavings from the hole.
Show/hide table
Illustration 45 g06338290 - Tap the hole with the roughing tap (20 mm Thread). Apply tapping fluid to the tap while you are tapping.
Show/hide table
Illustration 46 g06338293 - Remove all metal shavings from the hole.
Show/hide table
Illustration 47 g06338299 - Tap the hole with the finishing tap (20 mm Thread). Apply tapping fluid to the tap while you are tapping.
- Remove all metal shavings from the hole.
Show/hide table
Illustration 48 g06338302 Show/hide tableIllustration 49 g06338304 - Remove the burrs from the hole with a file.
Show/hide table
Illustration 50 g06338307 - Tap the hole again with the finishing tap (20 mm Thread) by using your hands.
Note: The finishing tap must bottom in the hole.
Show/hide tableIllustration 51 g06338311 Show/hide tableIllustration 52 g06338316 - Clean the hole and the insert to remove all the oil and the metal shavings.
Show/hide table
Illustration 53 g06338322 - Apply a liberal amount of sealant to the insert and the hole.
Show/hide table
Illustration 54 g06338324 - 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).
Show/hide tableIllustration 55 g06338327 - Torque the insert until the washer on the installation tool is flush with the deck of the block.
Show/hide table
Illustration 56 g06338331 - Remove the Insert Installation Tool (20 mm Thread).
Show/hide table
Illustration 57 g06338334 Show/hide tableIllustration 58 g06338335 - Clean the hole and the surface.
Illustration 40 | g06338275 |
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
Minimum Surface Texture Before Spray | |
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 | |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
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 |
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 |
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 |
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Chamfer | All edges must have at least |
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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 |
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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 | |
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Blast Nozzle to Work Distance | |
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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. |
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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 | |
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Air Jets/Pressure | |
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||
Arc Load Volts | 30V | 30V | ||
Amps | 125 Amps | 150 Amps | ||
Gun to Work Distance (Standoff) | |
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Approx. Spray Rate/Pass | |
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Gun Fixturing Method | Machine mount or hand held | |||
Traverse Rate of Gun | |
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Finishing Equipment | Rottler 99Y or similar | |||
Part/Cutter Rotation (Roughing) | Roughing |
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Part/Cutter Rotation (Finishing) | Finishing |
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Traverse Speed | |
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Depth of Rough Cut | First pass should remove at least |
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Depth of Finish Cut | |
Flame Spray Equipment and Procedure
NOTICE |
---|
Flame spray is not a validated or approved process for spraying under top supported liner flanges. |
Minimum Surface Texture Before Spray | |
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 |
Finishing Allowance | Machine |
Spray Angle | 90° |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
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 |
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. |
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 |
|
Chamfer | All edges must have at least |
|
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 |
|
Precautions and care must be taken to properly mask and remove all grit from block surface and cavities.
Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance. |
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Grit Blast Equipment | Pressure type only | |
Grit Type and Size | 24 mesh aluminum oxide | |
Blast Air Pressure | |
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Blast Nozzle to Work Distance | |
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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 |
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Oxygen Pressure | |
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Oxygen Flow | |
|
Fuel Gas Pressure | |
|
Fuel Gas Flow | |
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Carrier Gas Pressure | |
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Carrier Gas Flow | |
|
Spray Rate/Build Up | |
|
Gun to Work Distance | |
|
Traverse Rate of Gun | |
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Gun Fixturing Method | Machine mount or hand held | |
Per Pass Thickness | |
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Finishing Equipment | Standard head and block grinder, Milling machine | |
Part/Cutter Rotation | |
|
Traverse Speed | Rough |
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Depth of Rough Cut | |
|
Depth of Finish Cut | |
Thermal Spray Procedures for Crankshaft Main Bearing Saddle Area
Illustration 59 | g06370992 |
Part Description
Base Metal | Cast Iron |
Hardness | N/A |
Arc Spray Equipment and Procedure
Maximum Surface Texture | |
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 | |
Substrate Temperature During Spraying Not to Exceed | |
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 |
Arc Spray | Procedure | Check List | ||
Clean Part | Degrease in hot caustic solution | |||
Undercut | Not required | |||
Chamfer | All edges - 45° to |
|||
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 | |
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Blast Nozzle to Work Distance | |
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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 | |
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Air Jets/Pressure | |
|
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Arc Load Volts | 30V | 30V | ||
Amps | 125 Amps | 150 Amps | ||
Gun to Work Distance (Standoff) | |
|
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Spray Rate/Bond Pass | |
|
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Consumable (Topcoat) | TAFA 30T | TAFA 30T | ||
Clamp Pressure | |
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Air Jets/Pressure | |
|
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Arc Load Volts | 31V | 31V | ||
Amps | 150 Amps | 175 Amps | ||
Gun to Work Distance (Standoff) | |
|
||
Spray Rate/Build Up | |
|
||
Traverse Rate of Gun | |
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Gun Fixturing Method | Hand held | |||
Finishing Equipment | Line boring machine | |||
Part/Cutter Rotation (Roughing) | Roughing |
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Part/Cutter Rotation (Finishing) | Finishing |
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Coolant | Oil based synthetic - 40:1 ratio | |||
Traverse Speed | |
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Depth of Rough Cut | |
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Depth of Finish Cut | |
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Additional Finish Method | Flex hone if necessary |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
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 | |
Spray Angle | 90° to bore |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | If desired |
Rotation/Traverse Device | Hand held |
Rotation/Traverse Speed | |
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 |
Flame Spray Process (6P-II) | Procedure | Check List |
Clean Part | Degrease in hot caustic solution | |
Undercut | Not required | |
Chamfer | All edges - 45° to |
|
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 | |
|
Blast Nozzle to Work Distance | |
|
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 |
|
Oxygen Pressure | |
|
Oxygen Flow | |
|
Fuel Gas Pressure | |
|
Fuel Gas Flow | |
|
Carrier Gas Pressure | |
|
Carrier Gas Flow | |
|
Spray Rate/Build Up | |
|
Gun to Work Distance | |
|
Rotation Speed of Part (RPM) | N/A | |
Rotation Speed of Part | N/A | |
Traverse Rate of Gun | |
|
Gun Fixturing Method | Hand held | |
Bond Pass/Thickness | |
|
Top Coat/Thickness | As required | |
Finishing Equipment | Line boring machine | |
Part/Cutter Rotation | |
|
Traverse Speed | |
|
Depth of Rough Cut | |
|
Depth of Finish Cut | |
|
Additional Finish Method | Flex hone if necessary |
Thermal Spray Procedures for Main Bearing Cap
Illustration 60 | g03513357 |
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 61 | g03334317 |
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. |
Main Bearing Cap Specifications | |||
---|---|---|---|
Engine Model | Dimension A | Dimension B | Dimension C |
3114 | |
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3116, 3126, 3126B | |
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Part Description
Base Metal | Hardness |
Cast Iron | 28 - 34 Rc |
Arc Spray Equipment and Procedure
Maximum Surface Texture | |
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 | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | Filtered shop air |
Rotation/Traverse Device | Lathe or headstock/tailstock arrangement, rotary turntable |
Rotation/Traverse Speed | |
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 |
Arc Spray | Procedure | Check List | ||
Clean Part | Degrease in hot caustic solution | |||
Undercut | Not required | |||
Chamfer | All edges - 45° x |
|||
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 | |
|||
Blast Nozzle to Work Distance | |
|||
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 | |
|||
Air Jets/Pressure | |
|
||
Arc Load Volts | 30V | 30V | ||
Amps | 125 Amps | 150 Amps | ||
Gun to Work Distance (Standoff) | |
|
||
Spray Rate/Bond Pass | |
|
||
Consumable (Topcoat) | TAFA 30T | TAFA 30T | ||
Clamp Pressure | |
|||
Air Jets/Pressure | |
|
||
Arc Load Volts | 31V | 31V | ||
Amps | 150 Amps | 175 Amps | ||
Gun to Work Distance (Standoff) | |
|
||
Spray Rate/Build Up | |
|
||
Rotation Speed of Part (RPM) | RPM varies depending on diameter | |||
Rotation Speed of Part | |
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Traverse Rate of Gun | |
|||
Gun Fixturing Method | Machine mounted or hand held | |||
Finishing Equipment | Milling machine, line boring machine | |||
Part/Cutter Rotation (Roughing) | |
|||
Part/Cutter Rotation (Finishing) | |
|||
Coolant | Oil based synthetic - 40:1 ratio | |||
Traverse Cut | |
|||
Depth of Rough Cut | |
|||
Depth of Finish Cut | |
|||
Additional Finish Method | Flex hone if necessary |
Flame Spray Equipment and Procedure
Maximum Surface Texture | |
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 | |
Spray Angle | 90° to bore |
Substrate Pre-Heat Temperature | |
Substrate Temperature During Spraying Not to Exceed | |
Auxiliary Cooling | A J Unit |
Rotation/Traverse Device | Hand held |
Rotation/Traverse Speed | |
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 |
Flame Spray Process (6P-II) | Procedure | Check List |
Clean Part | Degrease in hot caustic solution | |
Undercut | Not required | |
Chamfer | All edges 45° x |
|
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 | |
|
Blast Nozzle to Work Distance | |
|
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 |
|
Oxygen Pressure | |
|
Oxygen Flow | |
|
Fuel Gas Pressure | |
|
Fuel Gas Flow | |
|
Carrier Gas Pressure | |
|
Carrier Gas Flow | |
|
Spray Rate/Build Up | |
|
Gun to Work Distance | |
|
Rotation Speed of Part | |
|
Traverse Rate of Gun | |
|
Gun Fixturing Method | Hand held | |
Bond Pass/Thickness | |
|
Top Coat/Thickness | As required | |
Finishing Equipment | Line boring machine | |
Part/Cutter Rotation | Standard | |
Traverse Speed | Standard | |
Depth of Rough Cut | |
|
Depth of Finish Cut | |
|
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 62 | g06278538 |
Example of protection for a component that is stored for a shorter term |
Illustration 63 | g06278539 |
Example of protection for a component that is stored for a longer period |