Reuse and Salvage for C-280 & 3600 Engine Cylinder Blocks {1201} Caterpillar

Caterpillar Products

All 3600 Engines

All C280 Engines

All G3600 Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8101
17	Added new serial number prefixes for New Product Introduction (NPI).
15–16	Combined information from SEBF2120, SEBF2121, SEBF2122, SEBF8151, SEBF8171, SEBF9169, added 2 part numbers and repaired 12 pixelated illustrations.
14	Added new serial number prefixes.

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

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

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

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

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

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Show/hide table

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

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

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

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

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

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

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

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

Summary

This guideline has the specifications for reusability of cylinder blocks that are used on the 3600 family of engines. If a cylinder block meets the specifications that are found in this guideline, then the cylinder block can be expected to give normal performance until the next overhaul when the cylinder block is used again in the same application.

Service Letters and Technical Information Bulletins

Show/hide table

NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Table 2

References
Media Number	Title
M0080689	Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure"
SEBD9339	Engine News, "Coolant Recommendation for 3618 Engines"
SEBF8148	Reuse and Salvage Guidelines, "General Salvage and Reconditioning Techniques"
SEBF8187	Reuse and Salvage Guidelines, "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"
SEBU7150	Operation and Maintenance Manual, "3618 Engine"
SEHS8869	Reuse and Salvage Guideline, "Cylinder Block Salvage Procedure Using Belzona® 1311 (Ceramic R Metal)"
SEHS8919	Reuse and Salvage Guideline, "Reuse and Salvage for Cast Iron Cylinder Blocks"
SMHS8418	Special Instruction, "Cylinder Block Cleaning Procedure"

Tooling and Equipment

Show/hide table

NOTICE
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3

Required Tooling and Equipment
Part Number	Description
1P-3047	Solid Handle Tap Wrench
1P-3537	Dial Bore Gauge Kit
1P-5571	Brush
1P-5572	Brush
1P-5573	Brush
1P-5602	7/64" Drill Bit
1P-5631	7/32" Drill Bit
1U-8152	5.2 mm Drill Bit
1U-9788	Brush
1U-9978	Acid Brush
1S-0258	Soft Face Hammer
4C-4774	Water and Temperature Resistant Grease
4C-5026	Slip Handle Tap Wrench
4C-6342	Brush
4C-6412	Electromagnetic Drill Press (No. 3 MT(1) Spindle, Variable Speed), 60 Hz
4C-6413	Electromagnetic Drill Press (No. 3 MT(1) Spindle, Variable Speed), 50Hz
4C-6410	Drill Press Mounting Plate Discontinued Refer to Step 4 for information on making the plate.
4C-6411	Head Stud Spacer Tube
4C-6415	Drill Bit with Pilot, 1 59/64 in (No. 3 MT(1))
4C-6414	Drill Bit-Extra Length, 1 59/64 in (No. 3 MT(1))
4C-6417	Tap with Pilot, 2-12 in thread
4C-6416	Tap-Extra Length, 2-12 in thread
4C-6418	Center (No. 31)
4C-6419	Drill Bit Stop Collar
4P-3138	Strainer
5C-9553	M6 X 1 Bolt
6V-1541	Quick Cure Primer
6V-2010	Polishing Stone
6V-2012	Depth Micrometer
6V-2196	Microscope
6V-3182	Brush
6V-3183	Brush
6V-7067	Brush
6V-7091	Brush
6V-7092	Brush
6V-7093	Brush
6V-7094	Brush
6V-7095	Brush
6V-7096	Brush
7E-8400	Taperlock Stud
8T-9290	Borescope
9A-1593	Surface Texture Comparison Gauge
9S-3265	Retaining Compound
9U-6241	Grinder
9X-6003	Nut
100-3115	1/4" -28 Set Screw
128-5113	Repair Insert(2)
174-6858	Cleaner
185-3998	Thread Lock Compound
187-0450	Taperlock Stud
223-1694	Dead Blow Hammer
237-5181	Respirator
263-9070	Steel File
274-7701	Bolt
303-9339	Lint Free Shop Towels
383-8887	Dual Scale Feeler Gauge Set
386-3364	Straight Edge Ruler
448-0722	Probe (17 mm Sideview Camera Borescope)
448-0723	Probe (5.5 mm HD Camera Borescope)
448-0724	Tool (Video Borescope - Wired)
448-0725	Tool (Video Borescope - Wireless)
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

(1)	MT = Morse Tapper
(2)	Order the number of inserts required to make the repair.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Show/hide table

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

Show/hide table

NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Initial Cleaning of the Engine

Illustration 3	g06238164

Cap all machined surfaces and plug all the hoses and fuel lines.

Clean all the external surfaces before the engine is disassembled. Clean all the external surfaces before the engine is brought into the shop. Use a high-pressure washer to spray the engine with hot water and soap or 174-6858 Cleaner.

Show/hide table

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.

Show/hide table

NOTICE
All reconditioned components should be cleaned again before assembly. Any debris or residue on the parts such as metal chips, carbon deposits, or sludge can enter the system. Debris or residue can cause early engine failures.

After the initial cleaning of the engine, disassemble the engine. Refer to the appropriate Disassembly and Assembly manual for your engine.

All fasteners should be compared against Reuse and Salvage Guidelines, SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines". Pay special attention to head bolts, main bolts, connecting rod bolts, and rocker shaft bolts when considering reusability. Any visual damage to the bolts should disqualify the bolt from reuse.

Note: Itis recommended to replace all cylinder head bolts and the spacer plates (if applicable) on any engine that has experienced a failure of the top deck/cylinder head joint.

Cleaning the Cylinder Block

One of the major reasons for a bearing failure after an engine overhaul is damage caused by debris in the oil passages. Remove all dirt, debris, and metal shavings from all openings, ports, and passages. Refer to M0080689Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure" for cylinder block cleaning.

Show/hide table

NOTICE
Failure to remove all dirt, debris, and/or metal shavings from openings, ports, and passages, will result in damage to the engine and the related components. A cylinder block that is not cleaned thoroughly will result in piston seizure or rapid wear of the cylinder bores, pistons, and piston rings. Only the thorough use of a rotary brush will correctly remove abrasive particles.

Schematics and Component Nomenclature

The following illustrations will help familiarize maintenance personnel with the nomenclature, lubrication schematics, and oil flow passages of C280 & 3600 engines.

Illustration 4	g03339691
C280 & 3600 oil flow through the Cylinder Block. See Table 4.

Table 4

C280 & 3600 Engine Oil Flow Through the cylinder block
Callout	Description
(2)	Piston cooling jets
(3)	Drilled passage in the cylinder block between the main oil gallery and the camshaft bearings
(7)	Drilled passage in the cylinder block between the main oil gallery and the crankshaft main bearings
(18)	Main oil Gallery
(19)	Piston cooling jet oil gallery
(20)	Drilled passage in the cylinder block between the camshaft bearing and the cylinder head
(21)	Tube
(22)	Rocker arm assembly

Illustration 5	g03339773
C280 & 3600 lubrication system layout.

Illustration 6	g03347856
3600 and C280 Engine Lubrication System

Table 5

C280 & 3600 Engine Lubrication Nomenclature
Callout	Description	Callout	Description
(1)	Oil temperature regulator	(10)	Oil Pump
(2)	Piston cooling jets	(11)	Prelube pump
(3)	Drilled passage in the cylinder block from the main oil gallery to the camshaft bearings	(12)	Oil Pump Suction Screen
(4)	Turbocharger oil supply line	(13)	Suction tube
(5)	Turbocharger	(14)	Priority valve
(6)	Turbocharger oil drain line	(15)	Oil filter change valve
(7)	Drilled passage in the cylinder block from the main oil gallery to the crank shaft main bearings	(16)	Oil Filters
(8)	Oil Pan/Base	(17)	Oil Coolers
(9)	Suction Bell	(23)	Centrifugal oil filter

Inspection Procedures

1. Check oil pump screen for debris

2. Check oil filter housing, dirty side, for debris

3. Check oil filter element, dirty side, for debris

4. Check oil filter element, clean side, for debris

5. Check oil supply pipes and the oil cooler for debris particles

If little or no debris particles are present during steps 1,2, or 3, there should be little concern that debris is in the clean side of the engine.

If debris particles are found during steps 4 or 5, flushing will be required. Always use pre-lube to flush the filter housing.

Check the clean side of the oil filter housing and lines to determine if debris particles are present. The latest oil design does not include a filter bypass. If debris particles are found past the oil filters, cut the filter to check for a burst or rupture in the filter paper. Inspect the filter element for foreign particles. A magnet may be helpful to separate non-ferrous metals like aluminum from ferrous metals like iron.

Inspect the turbocharger supply tube assembly, priority valve, and the oil manifold for any debris.

Inspect the oil cooler, oil pump, oil pan, and oil pump inlet screen for debris particles. Generally the oil pump screens should be replaced rather than cleaned.

The above inspections allow a person to determine the amount of cleaning required. If more cleaning is attempted than what is required, increased rebuild cost and unneeded risks will be taken. If a major engine failure has occurred and extensive debris is throughout the oil system, a major cleaning process will be required. Generally, a major cleaning requires a complete engine disassembly, which includes the removal of the crankshaft from the cylinder block.

Cleaning Recommendations

The following cleaning recommendations cover general cleaning, cleaning of the block and oil passages, and inspection after the cleaning process.

Show/hide table

Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

1. When cleaning any part of the engine, use only filtered water from a municipal or remote water system

2. Use a high-pressure steam spray machine to thoroughly clean the exterior of the engine before disassembling.

3. The engine must be disassembled and all plugs removed from all oil passages. Small components must be disassembled and cleaned.

4. The interior and exterior of the engine block can be cleaned with hot water spray equipment that delivers approximately 19 L/min (5 US gpm) flow of 82° C (180° F) cleaning solution at 5170 kPa (750 psi).

1. Place the cylinder block on 610 mm (24 inch) steel beams to provide access to the underside of the cylinder block

2. Elevate one end of the block to permit better drainage and easier testing of the main oil gallery. Flush the main gallery continuously with 47 L/min (12 US gpm) clean water flow.

3. All drilled oil passages should be cleaned to remove any oil present. Use a “Jumbo Jiffy” spray system with compressed air at 620 kPa (90 psi), hot water at 66° C (151° F).

4. Clean each oil passage individually, to avoid cross-contamination. Clean and flush each intersecting passage with filtered water. Then plug all passages and/or block water flow to that passage to avoid cross-contamination.

   Note: Do NOT use wire brushes for cleaning because the bristles can damage the machined surfaces. The wire strands can also break off and become lodged in oil passages and can cause damage and an increased chance of failures.

5. All passages should be cleaned with nylon bristle brushes several times to dislodge material. Use the brush, cleaning solution, and water to flush the debris oil of the oil passages, After cleaning, use water to wash the rest of the oil passages, Finally, use an air hose to dry the cylinder block.

The following brushes are required to clean the block.

Table 6

Brushes Required for Cleaning
Brush Part No.	Brush Diameter	Brush Part No.	Brush Diameter
6V-7067	6 mm (0.24 inch)	6V-7093	25 mm (0.98 inch)
6V-3182	8 mm (0.31 inch)	1P-5573	32 mm (1.26 inch)
1P-5571	10 mm (0.39 inch)	6V-7094	38 mm (1.5 inch)
6V-3183	11 mm (0.43 inch)	6V-7095	45 mm (1.8 inch)
6V-7091	13 mm (0.51 inch)	6V-7096	51 mm (2.01 inch)
6V-7092	16 mm (0.63 inch)	4C-6342	89 mm (3.50 inch)
1P-5572	19 mm (0.75 inch)	1U-9788	127 mm (4.99 inch)

Note: Use only the brushes listed in Table 6 for cleaning the block. Replace any brush that has worn or loose bristles.

All cleanliness evaluations are based on flushing a passage with solvent, filtering, and then evaluating the particles by their three-dimensional sizes.

Note: A passage is defined as the shortest distance that can be individually tested for cleanliness.

Here is an example of the method for checking cleanliness: take a turbocharger oil supply tube and spray the inside the tube with a solvent. For small parts, 4C-4079 Aerosol Spray Solvent or 8T-9011 Pump Spray Solvent will be satisfactory. For large parts, use a pressure spray gun. Collect and then flush the solvent through a paper patch or a clean white towel.

The cleanliness requirements must be met at the time of engine assembly. If a part fails the requirements, it must be cleaned and tested again.

1. The cleaned oil passages must be checked for cleanliness by flushing the passages. Flush the fluid through the passage, and collect it in a glass beaker so that a visual inspection can be made of the fluid. Filter the captured fluid through an 8 micron filter patch. The resulting collection of particles can then be measured.

2. The solvent will dissolve all the oil and evaporate quickly, leaving only carbon and/or metal particles. These particles should be inspected with a 6V-2196 Microscope to determine size.

3. Particles to be measured for size are metallic, slag, sand, or rust. Soft materials such as fibers or rubbers should not be included. If the particles are fragile and will break up when gently probed, the remaining broken pieces should be measured. These measurements should be compared to the dimensions in the next section. Section "Dimensions of Removed Particles".

Particles must meet the following requirements or the passage must be recleaned:

1. Unfiltered engine oil passages must not have any particles larger than a cylinder measuring 2 mm (0.08 inch) diameter and 0.2 mm (.008 inch) high. There should not be more than four particles larger than 1 mm (0.04 inch) diameter per passage.

2. Filtered engine oil passages must not have any particles larger than a cylinder measuring 1.2 mm (0.047 inch) diameter and 0.2 mm (.008 inch). There should not be more than four particles larger than 0.5 mm (0.02 inch) in diameter per passage.

After a major engine rebuild, steps must be taken to ensure the quality of the cleaning procedures. When starting a new or overhauled engine, the following procedures are suggested:

1. Install a 4P-3138 Strainer at the turbocharger oil inlet, with a screen extending downward into the turbocharger housing.

2. Install a temporary 152 mm (6.0 inch) strainer and a 127 mm (5.0 inch) strainer in each water inlet line to the engine.
   Show/hide table

   NOTICE
   When the strainers remain clean after 15 minutes of engine operation, remove them. Do not leave the strainers in the engine systems.

3. Start the engine at low idle and then slowly increase rpm to rated speed. The expansion tank pressure cap should be removed to allow air to vent from the cooling system. Be prepared to add water to the system.

4. Operate the engine at rated speed for 15-30 minutes. Drain the cooling system enough to remove temporary strainers. Remove the turbocharger oil line strainer. Clean the strainers and then reinstall. Operate the engine again at rated speed for 15 minutes. Remove the strainers, and check cleanliness. Continue this procedure until strainers are clean after 15 minutes of engine operation.

5. Reinstall the expansion tank pressure cap when the cooling system is completely vented.

6. Operate the engine under the following steps:
   Show/hide table

   Table 7

   Minutes	Load
   30	10%
   60	25%
   60	50%
   60	75%
   60	100%

7. Fifteen minutes after each load point is achieved, record all operating data for the engine parameters. Continue to monitor operating parameters during the entire load procedure.

8. Review all operating data to ensure that proper system operation before engine is returned to normal service.

9. After eight hours of normal operation, the engine should be shut down and an oil sample taken. All oil filters from each bank should be removed, cut apart, and evaluated for debris. Make sure that the water and turbocharger oil line strainers are removed.

10. Oil samples should be monitored closely after a major engine overhaul at normal 250-hour intervals.

Specifications for C280 & 3600 Engine Cylinder Blocks

Show/hide table

NOTICE
One major reason for bearing failure following an engine overhaul is damage cause by debris that was not removed from the oil passages that are in the engine block. Appropriate cleaning processes should be used when overhauling 3600 Engines and can be found in the service manual for each engine model.

Illustration 7	g06306917
Cylinder block for 3606 and 3608 Engines and C-280 6 cylinder and 8 cylinder (A) Camshaft bore (B) Main bore (C) Top deck to centerline of crankshaft (1) Side bolts (2) Studs of the main bearing cap (3) Main bearing cap nuts (4) Surface texture of the main bore

Illustration 8	g06306919
Cylinder block for 3612 and 3616 Engines and C-280 12 and 16 cylinder engines (A) Camshaft bore (B) Main bore (C) Top deck to centerline of crankshaft (1) Side bolts (2) Studs of the main bearing cap (3) Main bearing cap nuts (4) Surface texture of the main bore

Illustration 9	g06306921
Cylinder block for 3618 Engines (A) Camshaft bore (B) Main bore (C) Top deck to centerline of crankshaft (1) Side bolts (2) Studs of the main bearing cap (3) Main bearing cap nuts (4) Surface texture of the main bore

Table 8

Critical Specifications for C280 & 3600
Item	Description	3606, 3608, 3612, 3616 and C-280 with 6, 8, 12 and 16 cylinders		3618
		Minimum	Maximum	Minimum	Maximum
(A)	Specifications for the Camshaft Bore
	Diameter of the bore of the block	183.98 mm (7.243 inch)	184.02 mm (7.245 inch)	195.17 mm (7.6838 inch)	195.21 mm (7.6854 inch)
	Installed Bearing Bore Diameter	173.95 mm (6.8484 inch)	174.05 mm (6.8523 inch)	185.361 mm (7.2977 inch)	185.401 mm (7.2992 inch)
(B)	Specifications for the Crankshaft Bore The studs for the main caps are torqued.
	Diameter of the bore of the block
	Standard OD Bearing	264.980 mm (10.4323 inch)	265.020 mm (10.4338 inch)	289.980 mm (11.4165 inch)	290.020 mm (11.4181 inch)
	1.0 mm (0.04 inch) Oversize OD Bearing	265.980 mm (10.4716 inch)	266.020 mm (10.4732 inch)	290.980 mm (11.4559 inch)	291.020 mm (11.4575 inch)
	2.0 mm (0.08 inch) Oversize OD Bearing	266.980 mm (10.5110 inch)	267.020 mm (10.5126 inch)	291.980 mm (11.4953 inch)	292.020 mm (11.4968 inch)
	Clearance Between Bearing and New Journal	0.265 mm (0.0104 inch) to 0.385 mm (0.0152 inch)
(C)	Top Deck to Centerline of Crankshaft	945.70 mm (37.232 inch)	946.15 mm (37.250 inch)	946.00 mm (37.244 inch)
(1)	Torque of the Side Bolt for the Main Bearing Cap(1)	1650.0 N·m (1217.00 lb ft)	2000.0 N·m (1475.00 lb ft)	1650.0 N·m (1217.00 lb ft)	2000.0 N·m (1475.00 lb ft)
(2)	Torque of the Studs of the Main Bearing Cap(1)	80 N·m (59.0048 lb ft)	120 N·m (88.5072 lb ft)	80 N·m (59.0048 lb ft)	120 N·m (88.5072 lb ft)
(3)	Tension of the Main Bearing Cap Studs.	62600.0 kPa (9080.00 psi)(2)	67400.0 kPa (9775.00 psi)(2)	122500 kPa (17767.4000 psi)(3)	127500 kPa (18492.6 psi)(3)
		107550 kPa (15599.0520 psi)(4)	115450 kPa (16744.8680 psi)(4)
(4)	Surface Texture of the Main Bore	0.63 µm (25.000 µinch)	2.5 µm (100.00 µinch)	0.63 µm (25.000 µinch)	2.5 µm (100.00 µinch)

(1)	Refer to the specifications manual for the procedure to torque.
(2)	Use 207-5034 Stud Tensioner Tool Gp to tension the studs of the main bearing cap.
(3)	Use 156-7165 Stud Tensioner Tool Gp to tension the studs of the main bearing cap.
(4)	Use 191-5320 Stud Tensioner Tool Gp to tension the studs of the main bearing cap.

Surface Condition of the Top Deck

Illustration 10	g06306928
Surface of the top deck

Flatness of the Top Deck

The measurement of flatness must not exceed 0.08 mm (0.003 inch) per 100.00 mm (3.937 inch) length. This does not apply to dimensions (E) and (D) which locate the seating surface for the cylinder liner. Flatness within dimensions (E) and (D) must be 0.05 mm (0.002 inch).

Dimensions

Table 9

Dimensions for the Sealing Surface of Cylinder Liner
D	Gas	353.0 ± 0.5 mm (13.8976 ± 0.0197 inch)
	Diesel	346.0 ± 0.5 mm (13.62 ± 0.02 inch)
E	Gas	375.0 ± 1.0 mm (14.76 ± 0.04 inch)
	Diesel

Surface Texture

There is a maximum of 3.2 µm (125.00 µinch) on the entire top deck. This does not apply within dimensions (D) and (E). The surface texture within dimensions (D) and (E) must be at least 1.6 µm (63.00 µinch).

Inspect the surface between dimensions (D) and (E) for signs of damage such as pitting and erosion. This surface must be smooth and free of nicks, gouges, or any damage that could result in incorrect seating of the liner.

Procedure To Salvage Cylinder Blocks With Damaged Cylinder Head Stud Threads

Note: This salvage procedure may be used on multiple threaded holes on the same cylinder.

Stud Removal and Installation

Removal Methods

There are several methods that can be used to remove a broken or seized cylinder head stud from an engine block. Make sure that all fuel, oil, and water openings in the cylinder block are sealed with caps.

Note: Do not use any studs that are removed using the methods in Steps 3, 4, and 5. Always follow the procedures listed in this Guideline on installation and preparation.

1. The stud can be removed with a 3/4 in drive ratchet or breaker bar using the square hole in the top of each stud.
   Show/hide table

   Illustration 11	g06306959
   Remove stud by locking two 9X-6003 Nut together with wrenches.

2. Install two 9X-6003 Nut (1) and tighten them together with wrenches as shown. This will lock the nuts to the cylinder head stud allowing it to be removed and installed with a wrench. The 9X-6003 Nut have a 2 9/16 in hex. Remove the stud by using the wrench on the bottom nut and install the stud by using the wrench on the top nut.
   Show/hide table

   NOTICE
   Be sure that welding equipment is correctly grounded when welding on or near the engine block. Incorrect grounding can damage engine bearings. Ground the welder to the cylinder head stud being removed or an adjacent stud.

   Show/hide table

   Illustration 12	g06306962
   Weld nut to top of a broken stud.

3. Weld the inside diameter of the nut to the top surface of a broken cylinder head stud as shown in Illustration 12 and remove it with a wrench.
   Show/hide table

   Illustration 13	g06306964
   Thread a 9X-6003 Nut onto stud and weld in place.

4. Place a 9X-6003 Nut on the stud threads, then weld in position as shown in Illustration 13. Use a wrench on the nut to remove the damaged stud.

5. Remove cylinder head stud with a pipe wrench, if stud projects far enough above the surface of the block. Do not damage the top deck surface.

After studs are removed, clean threaded holes in cylinder block with a wire brush and 8T-9011 Component Cleaner. Use a soft towel or vacuum to remove cleaning solvent from the holes.

Note: Do not use compressed air to remove solvent from the threaded holes in the block. The compressed air may blow moisture and debris into the cylinder liners and adjacent openings.

Installation Procedure

Install cylinder head studs using either two

9X-6003 Nut or using a 3/4 in square drive ratchet/breaker bar in the end of the stud. Do not use any method for installing studs that can damage or create stress risers on the studs.

1. Coat entire length of the new Stud with 4C-4774 Water and Temperature Resistant Grease 454 gram (16 ounce) [cartridge].

2. Thoroughly clean the top of the cylinder block.

3. Install the stud and tighten to 100 ± 20 N·m (75 ± 15 lb ft).

Apply a bead of 4C-4774 Water and Temperature Resistant Grease around each stud at the top deck surface. The counterbore in the top of the block should be filled with grease.

Salvage Instructions

1. Remove the cylinder head stud from the hole with damaged threads. Refer to "Stud Removal and Installation" for procedures to remove studs. Clean cylinder head stud hole of any foreign material and debris.

2. Remove combustion seal ring for cylinder liner.

3. Create the Drill Press Mounting Plate
   Show/hide table

   Illustration 14	g06306934

4. Install the Drill Press Mounting Plate over the three remaining cylinder head studs to cover top of block and cylinder liner.

5. Install three 4C-6411 Spacer Tubes over cylinder head studs.

6. Install three cylinder head stud nuts to secure mounting plate to cylinder block.

7. Position 4C-6412 or 4C-6413 Magnetic Drill Press and 4C-6415 Drill Bit with pilot over the stud hole to be salvaged.
   Show/hide table

   NOTICE
   Do not allow drill bit to fall on the surface of the block. It is possible to damage both the block and/or the cutting edges of the drill bit.

8. Lower the multi-fluted drill bit slowly until pilot touches the threaded hole and is flush with top surface of cylinder block.

9. Engage magnetic power switch to secure drill press to mounting plate.
   Show/hide table

   NOTICE
   Always use cutting oil during drilling and tapping. Lack of lubricant reduces the life of the tooling. Drilling and tapping without correct lubricant can also result in oversized holes.

10. Turn feed handle for drill press upward until cutting edges are approximately 3.0 mm (0.11811 inch) from block surface. Lubricate pilot and hole, then rotate drill bit by hand before turning ON the drill press. The pilot must rotate freely to ensure drill bit is straight and centered on the drilled hole.

11. Adjust drill press to lowest rpm possible. Turn drill press motor ON and slowly feed drill bit down to start cutting. Do not force drill bit into block. Allow the drill bit to do the cutting.

12. Drill hole to 100.0 mm (4.00 inch) deep with the piloted drill bit. Do not force the pilot into tapped hole at bottom of cylinder head stud bore.

13. Remove piloted drill bit and install 4C-6414 Extra Length Drill Bit.

14. Install 4C-6419 Stop Collar on drill bit. Adjust stop collar to drill 265.00 mm (10.433 inch) deep and tighten the set screw with an Allen wrench. Drill hole to recommended depth.

15. Remove drill bit and install 4C-6418 Center Tool. The center tool will help keep tap straight with drilled hole.

16. Install 4C-6417 Tap with pilot in drilled hole. Lower centering tool to the machined center of the tap. This will ensure that the tap is centered and straight and also will provide a slight downward pressure to help in tapping the hole. Lubricate the tap.

17. Tap hole 100.0 mm (4.00 inch) deep. Do not force the pilot into the bottom of the drilled hole.

18. Remove the piloted tap. Install and lubricate 4C-6416 Extra Length Bottom Tap. Finish tapping the hole to a depth of 265.0 mm (10.433 inch).

19. Remove tap and clean the hole of any chips and debris.

20. Spray the repair insert with 6V-1541 Quick Cure Primer to remove any oil and grease and to speed the hardening process of the retaining compound.

21. Put 9S-3265 Retaining Compound on the outside diameter of the insert. Install the insert into the block using a 7E-8400 Taperlock Stud or 187-0450 Taperlock Stud and two 9X-6003 Nuts or a ratchet/breaker bar. The insert will be approximately 5.0 mm (0.20 inch) above the surface of the block deck when installed. Allow the retaining compound to harden about 2 to 3 hours.

22. Remove the cylinder head stud used to install the insert. Do not use any cylinder head studs that are damaged with nicks or wrench marks.

23. Use a 9U-6241 Grinder to grind the top of the insert to within 0.5 mm (0.02 inch) of the surface of the cylinder block. Use a file to remove the last 0.5 mm (0.02 inch) of material from the insert until the insert is flush with the top of the cylinder block.

Note: When grinding and filing the insert, do not remove material, or damage the top of the cylinder block.

Refer to "Installation Procedures" in this guideline for the procedure to coat the cylinder head studs with 4C-4774 Water and Temperature Resistant Grease.

Procedure for Cavitation Erosion in the Cylinder Block Bore of 3618 Engines

Illustration 15	g06307215
Area of erosion in the cylinder block bore (1) Ridge (2) Passages for the engine coolant (3) Erosion

Illustration 15 shows an example of erosion that is caused by cavitation in the cylinder block bore. Engine coolant is pumped upward between the cylinder block and the cylinder liner. The coolant flows over ridge (1) into passages (2). The restriction of the coolant causes turbulence under high pressure in this area. Erosion (3) can result.

Cavitation is typically concentrated at the outboard surfaces of the cylinder liner and at the outboard surfaces of the cylinder block cooling passages on the right side of the engine. This damage may also appear on the inboard side of the cylinder liner and in the cylinder block's cooling passages on the left side of the engine.

Note: The right and left sides of the engine are determined by the view from the flywheel end of the engine.

The damage is removed by machining of the cylinder block bore and/or by grinding of the bore. The repair is completed with an application of Belzona® 1311 (Ceramic R Metal).

Determining the Need for Repair

Cavitation in the cylinder block must be repaired when the depth of the damage reaches 10 mm (0.39 inch). The depth of the damage can be measured with a stiff wire of a diameter that is less than 1 mm (0.04 inch) or with a small needle.

Scheduling the Repair

Performance of this procedure is recommended during the engine's major overhaul. Generally, a major overhaul is performed after approximately 20,000 service hours. Down time and total repair costs are reduced when the procedure is performed during the major overhaul.

Replacement of the cylinder liners is recommended when the cylinder block is repaired.

Prevention of Cavitation Erosion

To help prevent the erosion, maintain the cooling system properly.

Follow the recommendations for coolant that is described in Engine News, SEBD9339, "Coolant Recommendation for 3618 Engines".

Perform the maintenance that is scheduled in Operation and Maintenance Manual, SEBU7150, "3618 Engine".

Differences in Repair Procedures for Serial Number Breaks

For engines S/N:2MW42-75, the cylinder block bore is machined to a diameter of 368 mm (14.49 inch). This simulates the cast open geometry for the cylinder block. The surface is ground and the repair is completed with Belzona® 1311 (Ceramic R Metal).

For engines S/N:2MW76-107, the cylinder block already has the cast open geometry and the cylinder block does not require machining. The areas that are damaged by cavitation are ground and the surface is repaired with Belzona® 1311 (Ceramic R Metal).

Repair Procedure for S/N:2MW00042-0075 Engines

Use the holes for the cylinder head studs to secure the fixtures for the machining to the engine. Alignment is referenced from the mounting face for the cylinder head.

1. Remove all cylinder heads, pistons, connecting rods, cylinder liners, and cylinder head studs.

2. To control contamination from debris, properly protect all openings in the engine. This includes plugging of the lower bore for the cylinder liner to help prevent contamination of the crankcase. Use covering to protect the surface area of the engine around the bore.

3. Install the required system for machining according to the recommendations of the supplier.

   • Machine the bore to a diameter of 368 mm (14.49 inch). Locate the top edge of the machining at a depth of 95 mm (3.74 inch) from the face of the cylinder's deck. Stop the machining at a depth of 180 mm (7.09 inch) from the face of the cylinder's deck.

   • Use a radius of 6 mm (0.24 inch) at the machining's points of transition.

4. After machining of the bore is complete, grind the remaining damaged area.

   The outer edges of the ground area must have a step with a depth of 5 mm (0.2 inch). This step provides a keyway for the application of Belzona® 1311 (Ceramic R Metal).

5. Use the grinding wheel to smooth the transition between the ground material and the material that is not ground. Do not allow any sharp edges to remain.

   If necessary, use a finer grinding wheel to smooth the ground surface.

   If the cavitation is deeper than 10 mm (0.39 inch), remove any edges of the holes that are sharp or uneven.

6. The area for the application of the Belzona® 1311 (Ceramic R Metal) must be prepared correctly. Surface preparation is critical for adhesion. Grit blasting is recommended for preparation of the surface.

7. After the grinding is completed, use a vacuum to remove the debris from the bore. Thoroughly wipe the bore to ensure cleanliness.

8. After the Belzona® 1311 (Ceramic R Metal) has been applied, use a machined form to shape the cylinder bore. The form also keeps the Belzona® 1311 (Ceramic R Metal) in place during the curing process.

9. After 24 hours of curing, dress the Belzona® 1311 (Ceramic R Metal) to remove excess material. Thoroughly remove any debris.

10. Remove the plug from the bottom of the bore. Remove the cover from the surface area of the engine around the bore.

11. Remove the crankshaft inspection covers from the sides of the engine. Thoroughly clean the oil pan.

Repair Procedure for S/N:2MW00076-00107 Engines

1. Remove all cylinder heads, pistons, connecting rods, cylinder liners, and cylinder head studs.

2. To control contamination from debris, properly protect all openings in the engine. This includes plugging of the lower bore for the cylinder liner to help prevent contamination of the crankcase. Use covering to protect the surface area of the engine around the bore.

3. Grind the damaged area.

   The outer edges of the ground area must have a step with a depth of 5 mm (0.2 inch). This step provides a keyway for the application of Belzona® 1311 (Ceramic R Metal).

4. Use the grinding wheel to smooth the transition between the ground material and the material that is not ground. Do not allow any sharp edges to remain.

   If necessary, use a finer grinding wheel to smooth the ground surface.

   If the cavitation is deeper than 10 mm (0.39 inch), remove any edges of the holes that are sharp or uneven.

5. The area for the application of the Belzona® 1311 (Ceramic R Metal) must be prepared correctly. Surface preparation is critical for adhesion. Grit blasting is recommended for preparation of the surface.

6. After the grinding is completed, use a vacuum to remove the debris from the bore. Thoroughly wipe the bore to ensure cleanliness.

7. After the Belzona® 1311 (Ceramic R Metal) has been applied, use a machined form to shape the cylinder bore. The form also keeps the Belzona® 1311 (Ceramic R Metal) in place during the curing process.

8. After 24 hours of curing, dress the Belzona® 1311 (Ceramic R Metal) to remove excess material. Thoroughly remove any debris.

9. Remove the plug from the bottom of the bore. Remove the cover from the surface area of the engine around the bore.

10. Remove the crankshaft inspection covers from the sides of the engine. Thoroughly clean the oil pan.

Alignment Check of the Main Bearing Bore

The alignment of the main bearing bores must be checked. Refer to the following illustrations and tables for the necessary information to inspect the alignment of the main bearing bores.

Illustration 16	g06307219
Dimensions for the line bore in C-280 6 and 12 cylinder engines and 3600 and 3612 Engines.

Table 10

Tolerances for the Position of the Line Bore in C-280 6 and 12 cylinder engines and 3600 and 3612 Engines
Main Bearing	Checked to Datum	Maximum Tolerance
2, 6	A-B	0.060 mm (0.0024 inch)
3, 5	C-D	0.060 mm (0.0024 inch)
4	E-F	0.060 mm (0.0024 inch)

Illustration 17	g06307224
Dimensions for the line bore in 3608 and 3616 Engines

Table 11

Position of the Line Bore Tolerances for C-280 8 and 126 cylinder engines and 3608 and 3616 Engines
Main Bearing	Checked to Datum	Maximum Tolerance
2, 8	A-B	0.060 mm (0.0024 inch)
3, 7	C-D	0.060 mm (0.0024 inch)
4, 6	E-F	0.060 mm (0.0024 inch)
5	G-H	0.060 mm (0.0024 inch)

Illustration 18	g06307233
Dimensions for the line bore in 3618 Engines

Table 12

Position of the Line Bore Tolerances for 3618 Engines
Main Bearing	Checked to Datum	Maximum Tolerance
2, 9	A-B	0.060 mm (0.0024 inch)
3, 8	C-D	0.060 mm (0.0024 inch)
4, 7	E-F	0.060 mm (0.0024 inch)
5, 6	G-H	0.060 mm (0.0024 inch)

Table 13

Available Crankshaft Bearings
Size	Part Number
	3606 3608 3612 3616 C-280	3618
Standard OD Standard ID	129-4054	137-1565
Standard OD 0.25 mm (0.010 inch) Undersize ID	127-1916 341-2600	N/A
Standard OD 0.5 mm (0.020 inch) Undersize ID	143-6219	N/A
Standard OD 1.0 mm (0.040 inch) Undersize ID	143-6221	N/A
0.5 mm (0.020 inch) Oversize OD Standard ID	N/A	144-9510
1.0 mm (0.040 inch) Oversize OD Standard ID	143-6222	144-9504
2.0 mm (0.080 inch) Oversize OD Standard ID	143-6224	N/A
1.0 mm (0.040 inch) Oversize OD 0.5 mm (0.020 inch) Undersize ID	127-1921 143-6223	N/A

Thermal Spray Procedures for Top Surface Deck

Spraying Under Top Supported Liner

Listed below are the arc and flame spray procedures for providing a sufficient thermal spray coating on top decks. Based on complexity and process variables, arc spray is the preferred technology for this process.

Arc spray is the only validated and approved process for spraying under top supported liner flanges. Flame spray should only be used for deck height recovery with the use of inserts under the liner flanges.

Arc Spray Equipment and Procedure

Table 14

Minimum Surface Texture Before Spray	3.2 µm (125.9843 µinch)
Reason for Spraying	Restore deck height to specification
Arc Spray Equipment Type	SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 75B Wire or equivalent Nickel Aluminum Wire
Max Spray Thickness	2.0 mm (0.08 inch) (Should Target 0.60 mm (0.024 inch) to 1.20 mm (0.05 inch) Spray Thickness)
Spray Angle	90°
Substrate Pre-Heat Temperature	22.2 °C (72.00°F) to 66°C (150.8°F) Do not direct arc on area to be sprayed.
Substrate Temperature During Spraying Not to Exceed	148°C (300°F)
Surface Preparation Method	Grit blast - If the entire mating surface is to be arc sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating, and can reduce material cost and finish machining time.
	Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Machining Method	Milling
Equipment Required	Rottler 99Y or similar
Recommended Cutting Tool	Sandvik R245 12T 3MPM 1010
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Finishing Equipment Type	Milling
Finishing Equipment	Rottler 99Y or similar

Table 15

Arc Spray		Procedure		Check List
Clean Part		Pre-machine block and degrease block deck surface.
		Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Undercut		Must not exceed 2.0 mm (0.08 inch) spray thickness
Chamfer		All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm (0.020 inch) chamfer.
Remove Oxide		Use fiber flap brush or Clean/strip disc
Clean Spray Area		Commercial degreaser ( Methyl Alcohol or Acetone)
Mask for Grit Blast		Grit blast - If the entire mating surface is to be arc sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating and can reduce material cost and finish grinding time.
		Precautions and care must be taken to properly mask and remove all grit from block surface and cavities.
Grit Blast Equipment		Pressure type only
Grit Type and Size		24 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 mm (2.0 inch) to 150 mm (6.0 inch)
Remove Blast Mask		Make sure that surface is clean
		Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Mask for Metal Spray		Tape, Metal Shield, Rubber, Metco Antibond, etc.
Metal Spray Equipment Type		Smart Arc by Oerlikon Metco	TAFA
	Consumable	TAFA 75B or Equivalent	TAFA 75B or Equivalent
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	152.4 mm (6.0 inch)	152.4 mm (6.0 inch)
	Approx. Spray Rate/Pass	0.08 mm (0.003 inch)/pass	0.08 mm (0.003 inch)/pass
Gun Fixturing Method		Machine mount or hand held
Traverse Rate of Gun		395.00 mm/s (1.296 Ft/s)
Finishing Equipment		Rottler 99Y or similar
Part/Cutter Rotation (Roughing)		Roughing 50 SMPM (150 SFPM)
Part/Cutter Rotation (Finishing)		Finishing 75 SMPM (250 SFPM)
Traverse Speed		0.30 mm (0.012 inch) per revolution
Depth of Rough Cut		0.51 mm (0.020 inch) per side max First pass should remove at least 0.178 mm (0.007 inch) to get below the peaks of the spray.
Depth of Finish Cut		0.25 mm (0.010 inch) per side max

Flame Spray Equipment and Procedure

Show/hide table

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

Table 16

Minimum Surface Texture Before Spray	3.2 µm (125.9843 µinch)
Reason for Spraying	Wear, erosion, center line distance too short to rework
Oerlikon Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 453
Finish Thickness	As required 0.25 mm (0.010 inch) to 0.38 mm (0.015 inch)
Finishing Allowance	Machine 0.64 mm (0.025 inch)
Spray Angle	90°
Substrate Pre-Heat Temperature	22.2°C (72.00°F) to 66°C (150°F)
Substrate Temperature During Spraying Not to Exceed	204°C (400°F)
Surface Preparation Method	Grit blast - If the entire mating surface is to be flame sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating, and can reduce material cost and finish machining time.
	Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Finishing Method	Machine
Grinding Equipment Type	Standard head and block grinder
Recommended Wheel	Norton 23A30E12VBEP or SGL abrasive HSA24F13-VKP
Machining Equipment Type	Mill
Recommended Cutter Grade	Sandvik 310-K-10 LNCX

Show/hide table

NOTICE
Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.

Table 17

Flame Spray Process (6P-II)	Procedure	Check List
Clean Part	Pre-machine block and degrease block deck surface.
	Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Undercut	Must not exceed 1.5 mm (0.06 inch) spray thickness
Chamfer	All edges must have at least 0.25 mm (0.010 inch) to 0.50 mm (0.020 inch) chamfer.
Remove Oxide	Use fiber flap brush or Clean/strip disc
	Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Clean Spray Area	Metco cleaning solvent or equivalent
Mask for Grit Blast	Grit blast - If the entire mating surface is to be flame sprayed, some shops prefer to pre-machine the surface. This process removes any major damage, allows for a recommended minimum 0.25 mm (0.010 inch) coating, reduces technique dependency in producing an even coating, and can reduce material cost and finish machining time.
	Precautions and care must be taken to properly mask and remove all grit from block surface and cavities. Time between surface preparation and thermal spray application should be minimal. Allowing excessive time between preparation and thermal spray will result in unacceptable coating performance.
Grit Blast Equipment	Pressure type only
Grit Type and Size	24 mesh aluminum oxide
Blast Air Pressure	690 kPa (100.0 psi)
Blast Nozzle to Work Distance	50 mm (2.0 inch) to 150 mm (6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
	Visual inspection for imbedded oils or other contaminants should be conducted during preheat.
Mask for Metal Spray	Tape, Metal Shield, Rubber, Metco Antibond, etc.
Metal Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Nozzle	6P-C7A-K "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling Air 140 kPa (20.0 psi) to 170 kPa (25.0 psi)
Oxygen Pressure	210 kPa (30.0 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	5.5 kg (12.00 lb) per hour 0.10 mm (0.004 inch) to 0.15 mm (0.006 inch) per pass
Gun to Work Distance	178 mm (7.0 inch)
Traverse Rate of Gun	36 SMPM (120.0 SFPM)
Gun Fixturing Method	Machine mount or hand held
Per Pass Thickness	0.10 mm (0.004 inch) to 0.15 mm (0.006 inch) per pass
Finishing Equipment	Standard head and block grinder, Milling machine
Part/Cutter Rotation	92.0 SMPM (300.00 SFPM)
Traverse Speed	Rough 203 mm (8.0 inch) per minute finish 38.1 mm (1.5 inch) to 51.0 mm (2.01 inch) per minute
Depth of Rough Cut	0.03 mm (0.001 inch) to 0.05 mm (0.002 inch) 0.25 mm (0.010 inch) to 0.38 mm (0.015 inch)
Depth of Finish Cut	0.03 mm (0.001 inch) 0.13 mm (0.005 inch) to 0.25 mm (0.010 inch)

Thermal Spray Procedures for Crankshaft Main Bearing Saddle Area

Illustration 19	g06370992

Part Description

Table 18

Base Metal	Cast Iron
Hardness	N/A

Arc Spray Equipment and Procedure

Table 19

Maximum Surface Texture	1.6 µm (62.99213 µinch)
Reason for Spraying	Bearing Failure
Mating Part Contact Area & Material	Crankshaft main bearing
Arc Spray Equipment Type	SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 30T Wire Top Coat, TAFA 75B Wire Bond Coat
Finish Thickness	As required
Spray Angle	90°
Substrate Pre-Heat Temperature	66.0° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148.0° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Hand held
Surface Preparation Method	Undercut and grit blast
Machining Method	Line bore
Recommended Cutting Tool	ISCAR DNMG 432 TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Finishing Equipment Type	Line boring machine

Table 20

Arc Spray		Procedure		Check List
Clean Part		Degrease in hot caustic solution
Undercut		Not required
Chamfer		All edges - 45° to 0.08 mm (0.0030 inch)
Remove Oxide		Use fiber flap brush or Clean/strip disc
Clean Spray Area		Commercial degreaser
Mask for Grit Blast		Use a metal mask or duct tape
Grit Blast Equipment		Pressure type only
Grit Type and Size		20 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask		Make sure that surface is clean
Mask for Metal Spray		Antibond or Blue Layout Dye
Metal Spray Equipment Type		Smart Arc by Oerlikon Metco	TAFA
	Consumable (Bondcoat)	TAFA 75B	TAFA 75B
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	128 mm (5.0 inch)	128 mm (5.0 inch)
	Spray Rate/Bond Pass	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Consumable (Topcoat)	TAFA 30T	TAFA 30T
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	31V	31V
	Amps	150 Amps	175 Amps
	Gun to Work Distance (Standoff)	166 mm (6.5 inch)	166 mm (6.5 inch)
	Spray Rate/Build Up	0.0023 mm (0.00009 inch)/pass	0.0023 mm (0.00009 inch)/pass
	Traverse Rate of Gun	11 SMPM (36 SFPM)
Gun Fixturing Method		Hand held
Finishing Equipment		Line boring machine
Part/Cutter Rotation (Roughing)		Roughing 50 SMPM (150 SFPM)
Part/Cutter Rotation (Finishing)		Finishing 75 SMPM (250 SFPM)
Coolant		Oil based synthetic - 40:1 ratio
Traverse Speed		0.30 mm (0.012 inch) per revolution
Depth of Rough Cut		0.51 mm (0.020 inch) per side max
Depth of Finish Cut		0.25 mm (0.010 inch) per side max
Additional Finish Method		Flex hone if necessary

Flame Spray Equipment and Procedure

Table 21

Maximum Surface Texture	1.6 µm (62.99213 µinch)
Reason for Spraying	Bearing failure
Mating Part Contact Area & Material	Crankshaft main bearing
Oerlikon Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 453 Grind 463
Finish Thickness	As required
Finishing Allowance	0.51 mm (0.020 inch) per side
Spray Angle	90° to bore
Substrate Pre-Heat Temperature	38° C (100° F)
Substrate Temperature During Spraying Not to Exceed	149° C (300° F)
Auxiliary Cooling	If desired
Rotation/Traverse Device	Hand held
Rotation/Traverse Speed	15 SMPM (50 SFPM)
Surface Preparation Method	Grit Blast
Finishing Method	Machine
Recommended Wheel	Norton 23A30E12VBEP or SGL abrasive HSA24F13-VKP
Machining Equipment Type	Line Boring Machine
Recommended Cutter Grade	ISCAR DNMG 432 TFIC507

Table 22

Flame Spray Process (6P-II)	Procedure	Check List
Clean Part	Degrease in hot caustic solution
Undercut	Not required
Chamfer	All edges - 45° to 0.08 mm (0.030 inch)
Remove Oxide	Use die grinder or flapper wheel
Clean Spray Area	Metco cleaning solvent or equivalent
Mask for Grit Blast	Use metal mask or duct tape
Grit Blast Equipment	Pressure type only
Grit Type and Size	24 mesh aluminum oxide
Blast Air Pressure	690 kPa (100.0 psi)
Blast Nozzle to Work Distance	51 mm to 150 mm (2.0 inch to 6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
Mask for Metal Spray	Metco Anti-Bond or blue layout dye
Metal Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Auxiliary Cooling	If desired
Nozzle	6P-7CA-K "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling Air 140 - 170 kPa (20.0 - 25.0 psi)
Oxygen Pressure	210 kPa (30.0 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	5.5 kg (12.00 lb) per hour 0.10 - 0.15 mm (0.004 - 0.006 inch) per pass
Gun to Work Distance	230 mm (9.0 inch)
Rotation Speed of Part (RPM)	N/A
Rotation Speed of Part	N/A
Traverse Rate of Gun	15 SMPM (50.00 SFPM)
Gun Fixturing Method	Hand held
Bond Pass/Thickness	0.13 mm (0.005 inch)
Top Coat/Thickness	As required
Finishing Equipment	Line boring machine
Part/Cutter Rotation	46 to 55 SMPM (150.0 to 180.0 SFPM)
Traverse Speed	0.08 mm (0.003 inch) or less
Depth of Rough Cut	0.25 mm to 0.51 mm (0.010 inch to 0.020 inch)
Depth of Finish Cut	0.13 mm to 0.25 mm (0.005 inch to 0.010 inch)
Additional Finish Method	Flex hone if necessary

Thermal Spray Procedures for Main Bearing Cap

Illustration 20	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 21	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.

Table 23

Main Bearing Cap Specifications
Engine Model	Dimension A	Dimension B	Dimension C
G3606B, G3608, G3612, G3616, 3606, 3608, 3612, 3616	265.000 ± 0.020 mm (10.4330 ± 0.0007 inch)	499.950 ± 0.030 mm (19.6830 ± 0.0011 inch)	275.000 ± 0.500 mm (10.8267 ± 0.0200 inch)
3618	290.000 ± 0.02 mm (11.41730 ± 0.00079 inch)	529.9550 ± 0.03 mm (20.86433 ± 0.00118 inch)	330.000 ± 0.500 mm (12.99210 ± 0.01969 inch)

Part Description

Table 24

Base Metal	Hardness
Cast Iron	28 - 34 Rc

Arc Spray Equipment and Procedure

Table 25

Maximum Surface Texture	1.6 µm (62.99213 µinch)
Reason for Spraying	Wear and/or bearing failure
Mating Part Contact Area & Material	Bearing sleeve and press fit
Arc Spray Equipment Type	SmartArc by Oerlikon Metco,TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 30T Wire Top Coat, TAFA 75B Wire Bond Coat
Finish Thickness	As required
Spray Angle	90°
Substrate Pre-Heat Temperature	66° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Lathe or headstock/tailstock arrangement, rotary turntable
Rotation/Traverse Speed	11 SMPM (36.00 SFPM)
Surface Preparation Method	Undercut and grit blast
Machining Method	Machine
Equipment Required	Mill, Line boring machine
Recommended Cutting Tool	ISCAR DNMG 432 TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)
Remarks	Badly discolored caps (heavily burned due to bad bearing failure) should not be rebuilt

Table 26

Arc Spray		Procedure		Check List
Clean Part		Degrease in hot caustic solution
Undercut		Not required
Chamfer		All edges - 45° x .76 mm (.030 inch)
Remove Oxide		Emery paper or glass beading (mating face), Flapper wheel - 60 grit (bearing sleeve)
Mask for Grit Blast		Metal mask type only
Grit Blast Equipment		Pressure type only
Grit Type and Size		20 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask		Make sure that surface is clean
Mask for Metal Spray		Use metal mask or METCO Anti-bond
Metal Spray Equipment Type		Smart Arc by Oerlikon Metco	TAFA
	Consumable (Bondcoat)	TAFA 75B	TAFA 75B
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	128 mm (5.0 inch)	128 mm (5.0 inch)
	Spray Rate/Bond Pass	0.038 mm (0.0015 inch) per pass	0.038 mm (0.0015 inch) per pass
	Consumable (Topcoat)	TAFA 30T	TAFA 30T
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	31V	31V
	Amps	150 Amps	175 Amps
	Gun to Work Distance (Standoff)	166 mm (6.5 inch)	166 mm (6.5 inch)
	Spray Rate/Build Up	0.058 mm (0.00228 inch) per pass	0.058 mm (0.00228 inch) per pass
	Rotation Speed of Part (RPM)	RPM varies depending on diameter
	Rotation Speed of Part	92 SMPM (300.00 SFPM)
	Traverse Rate of Gun	11 SMPM (36.00 SFPM)
Gun Fixturing Method		Machine mounted or hand held
Finishing Equipment		Milling machine, line boring machine
Part/Cutter Rotation (Roughing)		50 SMPM (150 SFPM)
Part/Cutter Rotation (Finishing)		75 SMPM (250 SFPM)
Coolant		Oil based synthetic - 40:1 ratio
Traverse Cut		0.30 mm (0.012 inch) per revolution
Depth of Rough Cut		0.51 mm (0.020 inch) per side max
Depth of Finish Cut		0.25 mm (0.010 inch) per side max
Additional Finish Method		Flex hone if necessary

Flame Spray Equipment and Procedure

Table 27

Maximum Surface Texture	1.6 µm (62.99213 µinch)
Reason for Spraying	Bearing failure
Mating Part Contact Area & Material	Crankshaft main bearing sleeve
Oerlikon Metco Equipment Type	6P-II by Oerlikon Metco
Metco Material	Metco 453
Finish Thickness	As required
Finishing Allowance	0.51 mm (0.020 inch) per side
Spray Angle	90° to bore
Substrate Pre-Heat Temperature	66° C (150.8° F) Do not direct flame on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (298.4° F)
Auxiliary Cooling	A J Unit
Rotation/Traverse Device	Hand held
Rotation/Traverse Speed	15 SMPM (50.00 SFPM)
Surface Preparation Method	Grit Blast
Finishing Method	Machine
Machining Equipment Type	Line Boring Machine
Recommended Cutter Grade	C-2, 883 Carboloy, or equivalent
Remarks	Badly discolored caps (heavily burned due to bad bearing failure) should not be rebuilt

Table 28

Flame Spray Process (6P-II)	Procedure	Check List
Clean Part	Degrease in hot caustic solution
Undercut	Not required
Chamfer	All edges 45° x 0.76 mm (0.030 inch)
Remove Oxide	Flapper wheel - 60 grit
Mask for Grit Blast	Use metal mask or duct tape
Grit Blast Equipment	Pressure or suction blast
Grit Type and Size	24 mesh aluminum oxide
Blast Air Pressure	690 kPa (100.0 psi)
Blast Nozzle to Work Distance	51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask	Remove mask, make sure that surface is clean
Mask for Metal Spray	Metco Anti-Bond or blue layout dye
Metal Spray Equipment Type	6P-II Hand Held Thermo Spray System by Oerlikon Metco
Auxiliary Cooling	METCO A J Siphon Air Jet
Nozzle	6P7-CK "K" Nozzle
Air Capacity/Pressure	6P-3/Cooling Air 140 kPa (20.0 psi)
Oxygen Pressure	210 kPa (30.0 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	5.5 kg (12.00 lb)/hr or 90 gr (3.2 oz)/min
Gun to Work Distance	230 mm (9.0 inch)
Rotation Speed of Part	91.4 m (299.869 ft)
Traverse Rate of Gun	15.24 m (50.0 ft)
Gun Fixturing Method	Hand held
Bond Pass/Thickness	0.13 mm (0.005 inch)
Top Coat/Thickness	As required
Finishing Equipment	Line boring machine
Part/Cutter Rotation	Standard
Traverse Speed	Standard
Depth of Rough Cut	0.25 to 0.51 mm (0.010 to 0.020 inch) per side
Depth of Finish Cut	0.13 mm (0.005 inch) or less per side
Additional Finish Method	Flex hone if necessary

-Do not direct flame on area to be sprayed.

-Excessive heat will cause cap draw in.

Storage Procedures

Proper protection of the cylinder block from corrosion is important. Corrosion will start in as little as one hour after the cylinder block has been cleaned.

When the cylinder block will not be inspected for one hour or less the cylinder block should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The cylinder block should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 22.

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 23.

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

Illustration 22	g06278538
Example of protection for a component that is stored for a shorter term

Illustration 23	g06278539
Example of protection for a component that is stored for a longer period