Inspection and Reconditioning Procedures of Main Bearing Bores in Cylinder Blocks {1201, 1202, 1224, 1224} Caterpillar


Inspection and Reconditioning Procedures of Main Bearing Bores in Cylinder Blocks {1201, 1202, 1224, 1224}

Usage:

769C 01X

Information for equipment:


BASIC ENGINE
CRANKSHAFT GP

New Front Crankshaft Seals and New Rear Crankshaft Seals are Now in Production {1160, 1161} 2003/05/01

New Front Crankshaft Seals and New Rear Crankshaft Seals are Now in Production {1160, 1161} 2003/05/01

Installing Crankshaft Seals And Wear Sleeves Using The Former 9S8868, 9S8873, 9S8881 And 9S8888 Tools Groups{1160, 1161, 0704} Installing Crankshaft Seals And Wear Sleeves Using The Former 9S8868, 9S8873, 9S8881 And 9S8888 Tools Groups{1160, 1161, 0704}
Installation Of Crankshaft Seals And Wear Sleeves{1160, 1161} Installation Of Crankshaft Seals And Wear Sleeves{1160, 1161}
Installation Of Crankshaft Seals And Wear Sleeves{1203} Installation Of Crankshaft Seals And Wear Sleeves{1203}
Use Of 1P4000 Line Boring Tool Group{0672, 1201, 1203} Use Of 1P4000 Line Boring Tool Group{0672, 1201, 1203}
Crankshaft Seal And Wear Sleeve Installation{1160, 1161} Crankshaft Seal And Wear Sleeve Installation{1160, 1161}
Installation Of Seal Groups With Hydrodynamic Grooves In The Seal Lip{1160, 1161} Installation Of Seal Groups With Hydrodynamic Grooves In The Seal Lip{1160, 1161}

Remove All 1140966 Crank Gears From Parts Stock Remove All 1140966 Crank Gears From Parts Stock






362-4250 Deck Height Measuring Tool{1201} 362-4250 Deck Height Measuring Tool{1201}
9U-5132 Timing and Fuel System Setting Tool Group{1105, 1162, 1290, 1905} 9U-5132 Timing and Fuel System Setting Tool Group{1105, 1162, 1290, 1905}
420-7630 Main Bearing Cap Lifting Device{0599, 0629, 0632, 0701, 1201, 1203, 1230} 420-7630 Main Bearing Cap Lifting Device{0599, 0629, 0632, 0701, 1201, 1203, 1230}

Remove All 1140966 Crank Gears From Parts Stock Remove All 1140966 Crank Gears From Parts Stock


Inspection and Reconditioning Procedures of Main Bearing Bores in Cylinder Blocks {1201, 1202, 1224, 1224} Inspection and Reconditioning Procedures of Main Bearing Bores in Cylinder Blocks {1201, 1202, 1224, 1224}
Reuse and Salvage for Crankshafts {0674, 1202} Reuse and Salvage for Crankshafts {0674, 1202}
Visual Inspection of Main Bearings and Connecting Rod Bearings {1202, 1203, 1225, 1230} Visual Inspection of Main Bearings and Connecting Rod Bearings {1202, 1203, 1225, 1230}
9U-5132 Timing and Fuel System Setting Tool Group{1105, 1162, 1290, 1905} 9U-5132 Timing and Fuel System Setting Tool Group{1105, 1162, 1290, 1905}
Reuse and Salvage for Engine Dampers {1202, 1205} Reuse and Salvage for Engine Dampers {1202, 1205}

Remove All 1140966 Crank Gears From Parts Stock Remove All 1140966 Crank Gears From Parts Stock

6V2086 And 6V2087 Seal And Wear Sleeve Installers Available{0622,1160,1161} 1980/09/01
New Connecting Rod And Main Bearings Have A Thicker Coating (Layer) Of Lead-Tin Overlay{1230,1219,1203} 1981/01/19
Crankshaft Failures; New Thrust Plate{1203,1202,1230} 1981/05/04
Engine Storage; Engine Start-Up After Storage{1000} 1982/02/22
Use 6V6035 Hardness Tester On Crankshafts{0651,1202} 1982/02/22
Use Correct Part Numbers For Main And Connecting Rod Bearings{1230,1203,1219} 1982/04/12
Inspection Marks On Bearings{7551,1230,1226,1203,1219,1227} 1982/05/03
New Crankshaft Main Bearings Used{1203} 1982/05/10
6V6142 And 6V6143 Installers Can Be Used To Install Crankshaft Seals And Wear Sleeves{0622,0626,1160,1161} 1982/11/01
Oil Passage Plugs Are No Longer Installed In Crankshafts For Parts Service{1202} 1983/04/04
New Connecting Rod Bearings Used{1219,1230} 1983/04/04
Procedure To Clean Oil Passages In Crankshafts And Cylinder Blocks{0622,0675,1201,1202} 1983/05/16
Reuse Of Engine Bearings{1230} 1983/05/16
Troubleshooting Engine Vibration; Damper Adapter Can Be Changed{1205,1000} 1983/08/15
New Connecting Rod And Main Bearings Used{1203,1219,1226,1227,1230} 1983/10/10
Crankshaft Failures{1202,1230} 1983/11/21
Reuse Of Engine Bearings{1230,1219,1203} 1983/11/21
Remanufactured Undersize Crankshafts Are Available{1202} 1983/11/21
Install Crankshaft Thrust Bearings Correctly To Avoid Damage{1202,1203} 1985/02/11
New Crankshaft Seal Groups Used On More 3400 Series Engines{1160,1161} 1985/03/11
Installing New Copper Bonded Bearings Can Extend Engine Life{1230,1203,1219} 1985/04/29
Remanufactured Crankshafts Are Available In Standard And Two Undersize Dimensions (U.S. and Canada){1202,7754} 1985/11/18
Crankshaft Seal Usage On 3400 Series Engines{1160,1161} 1985/12/16
Service Reminders For 3400 Family Of Diesel Engines{1204,1214,1331} 1986/05/05
Bearing Failures On Engines Due To Lack Of Lubrication{1230,1219,1203,1202} 1986/09/08
Improved Main And Connecting Rod Bearings Have Aluminum Alloy With More Strength{1230} 1977/01/17
Tools To Remove Wear Sleeves From Crankshafts{0621,7558} 1977/04/18
Tools To Install Crankshaft Seal And Wear Sleeve{1160,1161,0622} 1977/07/11
Some Wobble Is Acceptable In Rubber Vibration Dampers For Crankshafts{1205} 1977/10/31
Crankshaft Support Groups Are Available To Measure Bent Crankshafts{0653,1202} 1977/11/07
Main And Connecting Rod Bearing Part Numbers {1203,1219,1230} 1987/01/26
Mid-Life Bearing Maintenance Recommendations {1203} 1987/09/14
Use New Main Bearings In Replacement Cylinder Blocks{1203,1201} 1978/06/12
Change In Procedure To Check Main Bearing Clearance{1203} 1978/08/28
New Centering Rings For Oversized Main Bearings{0665,1230} 1979/06/04
New Design Thrust Plate Used In Crankshaft Group{1201,1202,1203} 1979/08/27
New Bronze Thrust Plate Used On Center Main Bearing Of Crankshaft Groups{1203} 1990/12/17
Checking Crankshaft Journal Surface Hardness On Remanufactured Crankshafts{1202} 1991/01/07
Oil Holes In Crankshaft Main And Rod Journals{1202} 1992/11/09
Use the 171-7212 Wear Sleeve to Repair the Crankshaft Hub {1160} 2011/09/20
40 Power Microscope is Available for Inspecting Bearing Journals on Crankshafts {0777, 1202} 2006/01/16


Caterpillar Products
All Cat Engines

Introduction

Table 1
Revision  Summary of Changes in SEBF9162 
25  Repaired 4 pixelated illustrations 
24  Added new serial number prefixes. 
23  Added new serial number prefixes. 

© 2018 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, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ 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 provides the inspection procedure and the reconditioning procedure for main bearing bores. This guideline applies to cylinder blocks for all engines regardless of bore size. Cylinder blocks that meet the requirement in this guideline and in the applicable guidelines for specifications can be expected to give normal performance in the same application until the next engine overhaul.

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 
SEBF8042  Reuse and Salvage Guidelines, "Reuse and Salvage for Crankshafts" 
SEBF8064  Reuse and Salvage Guidelines, "Reuse and Salvage for Connecting Rods" 
SEBF9008  Reuse and Salvage Guidelines, "Reuse and Salvage for 3400 and C-Series Engine Cylinder Blocks" 
SEHS7606  Special Instruction, "Use Of 1P-4000 Line Boring Tool Group" 

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  Quantity 
1P-2344 Standard  Centering Ring for engines with 114.30 mm (4.500 inch) bore  As needed 
6V-0138 Oversize 
1P-2351 Standard  Centering Ring for engines with 158.80 mm (6.252 inch) bore  As needed 
6V-0145 Oversize 
1P-3537  Dial Bore Gauge Kit 
1P-4000  Line Boring Tool Group 
1U-8869  Dial Indicator 
3P-1568  Dial Indicator 
5P-2381 Standard  Centering Ring for engines with 137.19 mm (5.401 inch) bore  As needed 
6V-0142 Oversize 
5P-6518  Dial Indicator Fixture 
6V-2012  Depth Micrometer 
9A-1593  Surface Texture Comparison Gauge 
185-3998  Thread Lock Compound  As needed 
263-9070  Steel File 
303-9339  Lint Free Shop Towels 
383-8887  Dual Scale Feeler Gauge Set 
386-3364  Straight Edge Ruler 
448-3698  Profilometer 
473-8688
or
473-8689 
Internal Micrometer Set
2-12 inch 
Internal Micrometer Set
50-300 mm
473-8690  Outside Electronic Micrometer Set
0-4 inch 
473-8691  Outside Electronic Micrometer Set
2-6 inch 

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.


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.


Inspection

Inspection of Bearings



Illustration 3g06305181
Uneven wear pattern on main bearings


Illustration 4g01449229
Uneven wear pattern on main bearings


Illustration 5g01450593
Uneven wear pattern on main bearings


Illustration 6g01450640
Uneven wear pattern on main bearings

  1. Inspect main bearings and thrust bearings for wear patterns. Look for side loading, uneven wear patterns, damage, and fretting.

Refer to Reuse and Salvage Guideline, SEBF8064, "Reuse and Salvage for Connecting Rods" for pictures and information about the wear of bearings.

Inspection of the Crankshaft



Illustration 7g06305185
Crankshaft on vee blocks with dial indicator

  1. Inspect the crankshaft journals for wear and damage.

  2. Inspect the oil holes for debris.

  3. Inspect the fillets for pitting and scalloped edges.

  4. Inspect the crankshaft for any damage to the counterweights.

Refer to Reuse and Salvage Guideline, SEBF8042, "Reuse and Salvage for Crankshafts" for more information regarding inspection of crankshafts.

Inspection of Main Bearing Caps



    Illustration 8g01436433
    (1) Fretting


    Illustration 9g01441317
    Physical damage to the saddle of the main bearing cap

  1. Main bearing caps should be visually inspected for any obvious damage.


    Illustration 10g01986344
    Inspection of flatness on main bearing cap

  2. After the visual inspection, the caps should be measured for flatness. Place the caps on a precise flat surface. If a 0.038 mm (0.0015 in) feeler gauge can fit under the flat surfaces of the cap, then the cap must be machined. Refer to "Procedure to Machine Main Bearing Caps" for the machining procedure.

    Note: The flatness of the precise flat surface should only vary 0.005 mm (0.0002 inch).

  3. Inspect the main bores for damage. Feel for galling or high spots on the bores.


    Illustration 11g06305193
    (2) Gap between the cap and block

  4. Install the main bearing caps on the cylinder block.

    Note: The location and orientation of the caps is critical.

  5. Inspect the width of the cap in relation to the width of the space in the cylinder block. Force the cap to one side.

  6. Insert a feeler gauge between the cap and the block. If a 0.040 mm (0.0016 inch) feeler gauge will fit, then the cap must be replaced or salvaged.

Inspection of Out of Round and Taper



    Illustration 12g01436907
    Positions to measure out of roundness

  1. Torque the caps to full torque. Refer to the appropriate specifications manual for the torque procedure and the tightening sequence.


    Illustration 13g01986348
    Measurement for out of round with a dial bore gauge

  2. Measure the main bores for the crankshaft with a dial bore gauge. Take measurements in the vertical position, the horizontal position, and 45° positions. These measurements will be used to determine if the bore is out of round. Refer to Illustration 12 for the out of round measurement.

  3. Take a vertical measurement in the front and rear of each bore. The difference between these two measurements is the taper of the bore.

Refer to the appropriate specifications manual for the specific information about both of these measurements. If the bores exceed specifications, then the bores must be machined. Refer to "Procedure to Line Bore Using the 1P-4000 Line Boring Tool Group" for the machining procedure.

Inspection of Alignment of Main Bores



    Illustration 14g01986359
    Boring bar in main bores

  1. Use the boring bar from 1P-4000 Line Boring Tool Group to check the main bores for alignment. Place the boring bar in the main bores.

  2. Roll the boring bar slightly in one direction. Place a 0.025 mm (0.0010 inch) feeler gauge onto the main bore.

  3. Allow the boring bar to roll over the feeler gauge. Pull on the feeler gauge. If there is resistance, then the bore is in alignment. If the feeler gauge is easily removed, then the bore is out of alignment. If the bore is out of alignment, line bore the block.

  4. Use this process in the same eight locations as the out of round measurement. Refer to Illustration 12 for the out of round measurement.

Refer to "Procedure to Line Bore Using the 1P-4000 Line Boring Tool Group" for information about the line boring process.

Repair Process

Note: This repair process is for components that do not pass the inspection.

Crankshaft

Refer to Reuse and Salvage Guideline, SEBF8042, "Reuse and Salvage for Crankshafts" for information about machining crankshafts.

Procedure to Machine Main Bearing Caps

Note: The flats of the main bearing caps should not be machined until Step 2 in "Procedure to Line Bore Using the 1P-4000 Line Boring Tool Group".



Illustration 15g01986475
An example of a boring machine setup.

  1. Position the vise on the boring machine. Use a dial indicator to indicate the vise to the spindle. Clamp the vise to the table.


    Illustration 16g01986499
    Remove burrs.

  2. Use a stone to remove any burrs from the opposite side.

  3. Place the cap into the vise. Clamp the vise. Tap on the cap with a soft hammer. This will locate the cap in the bottom of the vise.


    Illustration 17g01986504

  4. Use a 0.025 mm (0.0010 inch) feeler gauge to verify the location of the cap in the vise.

    Note: Make this verification on both sides of the cap.



    Illustration 18g01986533

  5. Remove 0.08 mm (0.003 inch) to 0.13 mm (0.005 inch) from both faces. Allow the cutter to move across both faces. It is not necessary for all caps to be the same height.

  6. Remove burrs.

Repeat step 1 through step 6 for the remaining caps.

Note: New replacement caps are available if machining the main caps is not the preferred method. If the caps are replaced, it is necessary to line bore the block.

Procedure to Line Bore Using the 1P-4000 Line Boring Tool Group



    Illustration 19g01986634
    (3) Boring Bar
    (4) Centering Ring

  1. Place centering rings in the first main bearing bore, the third main bearing bore, the fifth main bearing bore, and the seventh main bearing bore.

  2. Remove 0.08 mm (0.003 inch) to 0.13 mm (0.005 inch) from both faces of the second main bearing cap, the fourth main bearing cap, and the sixth main bearing cap. Refer to "Procedure to Machine Main Bearing Caps" for the machining procedure.

  3. Install the second main bearing cap, the fourth main bearing cap, and the sixth main bearing cap.

  4. Torque all the main bearing caps to full torque. Refer to the appropriate specifications manual for the torque procedure and the tightening sequence.


    Illustration 20g01986654
    The dial indicator is being used to set the size of the cutting tool.


    Illustration 21g01986656
    Boring bar with cutting tool

  5. Set the cutting tool to the appropriate size. Use the information from "Inspection" to determine the appropriate size. Refer to the corresponding specifications manual.

  6. Apply oil to the centering rings and the boring bar. Place boring bar in centering rings. Install the cutting tool onto the boring bar.


    Illustration 22g01986673
    Hydraulic Drive

  7. Verify that the hydraulic drive is moving in the correct direction.


    Illustration 23g01986337

  8. Use a drill to turn the boring bar. Use a swivel joint from the 1P-4000 Line Boring Tool Group with the drill. This will help avoid mistakes.

  9. Machine the second main bearing bore, the fourth main bearing bore, and the sixth main bearing bore. Do not move the centering rings until these bores have been completed.


    Illustration 24g06305252
    The clamp (5) is holding the centering ring (4) in place.

  10. Move the centering rings to the second main bearing bore, the fourth main bearing bore, and the sixth main bearing bore.

  11. Remove 0.08 mm (0.003 inch) to 0.13 mm (0.005 inch) from both faces of the third main bearing cap and the fifth main bearing cap. Refer to "Procedure to Machine Main Bearing Caps" for the machining procedure.

  12. Install the third main bearing cap and fifth main bearing cap. Torque the third main bearing cap and fifth main bearing cap to full torque. Refer to the appropriate specifications manual for the torque procedure and the tightening sequence.

  13. Machine the third main bearing bore and the fifth main bearing bore.

    Note: Clamps may be necessary to keep centering rings in place.



    Illustration 25g01986748
    (6) Upright Bearing Assembly
    (7) Bridge Assembly

  14. Place the bridge assembly on the block. The bridge assembly must be in front of the seventh main bearing bore.

  15. Bolt the bridge assembly to the block. Do not tighten the bolts at this time. Refer to Illustration 25.

  16. Install the upright bearing assembly into the bridge assembly. Tighten the bolts by hand.

  17. Install the boring bar through the centering rings and bearing assembly.

    1. Slide the boring bar back and forth while the bolts are being tightened. This will allow the upright bearing assembly to be aligned with the other bores.

    2. Move the boring bar out of the upright bearing assembly. Slowly move the boring bar in the upright bearing assembly. Listen and feel for any contact. If any contact is detected, the upright bearing assembly is not aligned with the other bores. Repeat this process until no contact occurs.

  18. Remove 0.08 mm (0.003 inch) to 0.13 mm (0.005 inch) from both faces of the seventh main bearing cap. Refer to "Procedure to Machine Main Bearing Caps" for the machining procedure.

  19. Install the seventh main bearing cap. Torque the seventh main bearing cap to full torque. Refer to the appropriate specifications manual for the torque procedure and the tightening sequence.

  20. Install the cutting tool on the boring bar outside one of the outer bores.

  21. Install the hydraulic drive and switch directions.

  22. Machine the seventh bore.

  23. Repeat steps 14 through 22 for the first main bearing bore.

  24. Verify the machining procedure. Place centering rings in the outer bores. Move the boring bar in and out of the centering rings. Listen and feel for any contact between the boring bar and the centering rings. If any contact is detected, the bores are not in alignment.

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