Reuse and Salvage for 3500 Engine Cylinder Blocks {0672, 0705, 0762, 1201, 1217} Caterpillar

Caterpillar Products

All 3500 Engines

All G3500 Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8255
42	Added new serial number prefixes for New Product Introduction (NPI) and changed cutoff length to mm.
41	Added part number for glass beads.
40	Combined guidelines SEBF2120, SEBF2121, SEBF2122, SEBF8219, SEBF8226, SEBF8291, SEBF8437, SEBF9203, SELD0458, and repaired 41 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 Cat 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 the safety of yourself and others. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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

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

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

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

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

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

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, 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 contains the specifications for the 3500 engine cylinder blocks and spacer plates. Spacer plates can often be reused with the same performance as new spacer plates. A cylinder block that meets the specifications in this guideline can be expected to give normal performance until the next overhaul.

Service Letters and Technical Information Bulletins

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

References

Table 2

References
Media Number	Title
M0080689	Reuse And Salvage Guidelines, "Cylinder Block Cleaning and Audit Procedure"
SEBF8068	Reuse and Salvage Guidelines, "Inspection and Reuse Guideline of Cylinder Liners in Cat Engines"
SEBF8301	Reuse and Salvage Guidelines, "Inspection and Reuse of Critical Fasteners Used in All Engines"
SEBF8357	Reuse and Salvage Guidelines, "General Cleaning Methods"
SEBF9238	Reuse and Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240	Reuse and Salvage Guideline, "Fundamentals of Flame Spray for Reconditioning Components"
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"
SEHS9031	Special Instruction, "Storage Procedures for Caterpillar Products"
SMHS7606	Special Instruction, "Use Of 1P-4000 Line Boring Tool Group"
SMHS7727	Special Instruction, "Use of 8T-0455 Cylinder Liner Projection Indicator Group"
SMHS8839	Special Instruction, "Using 5P-4175 Boring Tool Group and 5P-1618 Counterboring Tool Group"
SENR1126	Disassembly and Assembly, "3500 and 3500B High Displacement Engines for Caterpillar Built Machines"

Tooling and Equipment

The tooling listed in Table 3 is for all salvage repairs. Some tools will not be required based on individual repair needs.

Table 3

Required Tools and Equipment
Part Number	Part Description
1P-3537	Dial Bore Gauge
2S-0115(1)	Hard Washer
4C-3845	Grinding Wheel
4C-9500	Quick Cure Primer
4C-9507	Retaining Compound
5P-0333(4)	Crowfoot Socket
5P-1630	Adapter
5P-1657	Shaft
5P-1769(2)	Washer
5P-4175(3)	Counterboring Tool Group
5P-4175	Counterboring Tool Group
6V-2012(4)	Depth Micrometer
6V-2025	Cutter Assembly
8H-0707	1/4 × 20 Allen Head Screw
8H-8559	Modified Extension Assembly
8T-0455(4)	Liner Projection Tool Group
8T-2682	Plate
9U-5271	Glass Beads
154-9731	Thread Lock Compound
169-5464	Quick Cure Primer
178-2502	3508 Main Bearing Threaded Insert
178-2503	3516 Main Bearing Threaded Insert
178-2351	Reamer
178-2353	Tap First Operation
178-2356	Tap Second Operation
178-2462	Reamer
178-2463	Tap First Operation
178-2465	Tap Second Operation
178-2467	Installation Sleeve
178-2468	Installation Sleeve
222-3117	Brake Cleaner
263-9070	Steel File
266-3736	Impact Wrench
303-9339	Lint Free Shop Towels
365-1197	Liner Brush
385-4007	Liner Seat Insert Installation Tool
386-3364	Straight Edge Liner
373-5840	Leak Test Tool for Liner Seat Insert
434-6509	Leak Test Tool for Water Ferrule Insert
441-3674	Water Ferrule Driver
448-3698	Profilometer
473-0493(5)	Insert Kit (Standard Diameter)
473-0494(5)	Insert Kit (Oversize Diameter)
473-8688 or 473-8689	Inside Micrometer Set 2-12 inch
	Inside Micrometer Set 50-300 mm
473-8690	Outside Electronic Micrometer Set 0-4 inch
473-8691	Outside Electronic Micrometer Set 2-6 inch
473-8692	Outside Electronic Micrometer Set 6-12 inch
489-0635	Insert Driver Tool
PT-2801	Basic Kit (Jig fixture)
PT-2801-3	Service Kit
PT-8760	Threaded insert used in 3500 Family Series Engine [current block style, 53.3 mm (2.10 inch) long]
PT-8762	Threaded insert used in 3500 Family Series Engine [old block style, 69.9 mm (2.75 inch) long]
-	Impact Socket
-	End Mill
-	Isopropyl Alcohol
-	Loctite 640

(1)	Use with the tools for the water ferrules
(2)	Use with the counterboring tool, the manual tool, and the insert installation tools
(3)	Additional information about this tool group can be found in Tool Operating Manual, NEHS1022.
(4)	Use with the counterboring tool
(5)	Each Insert Kit includes one insert and one integral seal

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

Measurement Techniques

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

Measurement Tooling include precision inside and outside diameter micrometers capable of measuring four decimal places in inches or three decimal places in millimeters. Measuring tools should be calibrated using gage blocks certified to a national standard such as the National Institute of Standards and Technology (NIST).

Ensure that several sample measurements are taken at different locations on the same feature. Measure diameters of internal bores in several places to identify tapered and or oval conditions.

Initial Cleaning of the Engine

Illustration 3	g06238164

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

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

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

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

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

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

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

Cleaning the Cylinder Block

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

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

Note: Do not use surface reconditioning pads on the top deck of the block, spacer plates, and cylinder head surfaces.

Specifications for 3500 Engine Cylinder Blocks

Specifications

Refer to Table 4 and Illustration 4 for dimensions and nomenclature of 3500 Engine specifications.

Illustration 4	g06181001
A typical cylinder block for 3500 Engines. Refer to Table 4 for specifications and dimensions.

Specifications for the Cylinder Block

Table 4

3500 Cylinder Block Specifications
Dimension	Description		Minimum	Maximum	Part Number
Specifications of the Camshaft Bore (A)
A	Diameter of the bore of the block A Series		91.980 mm (3.6213 inch)	92.020 mm (3.6228 inch)	N/A
	Installed bearing bore diameter A Series		85.94 mm (3.383 inch)	86.06 mm (3.388 inch)	N/A
	Diameter of the bore of the block B Series		97.980 mm (3.8575 inch)	98.020 mm (3.8590 inch)	N/A
	Installed bearing bore diameter B Series		91.980 mm (3.6213 inch)	92.100 mm (3.6260 inch)	N/A
Specifications of the Crankshaft Bore (B) After Torquing the Main Bearing Cap Bolts
B	Diameter of the Bore of the Block
	Standard bore		169.722 mm (6.6820 inch)	169.762 mm (6.6835 inch)	N/A
	0.63 mm (0.25 inch) oversize bore		170.352 mm (6.7068 inch)	170.392 mm (6.7083 inch)	N/A
	ID of the Installed Bearing
	Standard ID of the bearing		160.142 mm (6.3048 inch)	160.211 mm (6.3075 inch)	149-6031
	0.63 mm (0.025 inch) undersize ID		159.507 mm (6.2798 inch)	159.576 mm (6.2825 inch)	149-6032
	1.27 mm (0.050 inch) undersize ID		158.872 mm (6.2548 inch)	158.941 mm (6.2575 inch)	149-6033
	0.63 mm (0.025 inch) oversize OD		160.142 mm (6.3048 inch)	160.211 mm (6.3075 inch)	149-6034
	0.63 mm (0.025 inch) undersize ID and oversize OD		159.507 mm (6.2798 inch)	159.576 mm (6.2825 inch)	149-6035
C	Surface texture of the main bore of the block		0.63 µm (24.803 µinch) Ra	2.5 µm (98.42 µinch) Ra	N/A
D	Dimension from the top deck of the cylinder block to center line of the crankshaft		585.40 mm (23.047 inch)(1)	New cylinder block	N/A
			585.62 mm (23.056 inch)(2)	586.00 ± 0.15 mm (23.071 ± 0.006 inch)	N/A
E	Dimension from horizontal center line of crankshaft bearing bore to bottom of block		229.65 mm (9.041 inch)	230.35 mm (9.069 inch)	N/A
F	Thickness of the spacer plate		Refer to "Specifications and Salvage for Spacer Plates"
G	Flatness of the top deck Refer to Illustration 5.	Shaded area (9)	0.00	0.05 mm (0.002 inch)	N/A
		Full length of block	0.00	0.15 mm (0.006 inch)	N/A
H	Angle of the top deck
	Angle		30 degrees	N/A
	Tolerance		±0.25°
I	Distance from center line of dowel hole to center line of crankshaft bore.		226 ± 0.06 mm (8.898 ± 0.002 inch)

(1)	3500 Series A Series Engines (MUI and EUI)
(2)	For 3500 Series B Series Engines including High Displacement Engines.

Top Deck Flatness Specification

The flatness specification (G), Table 4 of the top deck must be contained to the required specification with the shaded area (9) for each cylinder. Refer to Illustration 5. The width of area (9) is 270.00 mm (10.630 inch) or the width of the area from either side of the center line of the bore is 135.00 mm (5.315 inch). This flatness requirement must be met for each cylinder bore.

Illustration 5	g01393805
Shaded area (9) must meet the flatness requirement (G) which is given in Table 4. (4) 135.00 mm (5.315 inch) (5) 270.00 mm (10.630 inch) (9) Surface of the top deck

Top Deck Surface Texture and Waviness Specifications

Inspect the surface of the top deck for signs of damage such as pitting or erosion. The surface must be smooth and free of nicks and gouges. The surface must be free of any damage that could result in an incorrectly seated liner or an incorrectly sealed gasket.

Table 5

Top Deck Surface Texture and Waviness Specifications
3500B Block	350-1412	Top Deck Surface Texture	2.5 µm (98.43 µinch) Ra Roughness Sampling Length or Cutoff - 2.54 mm (0.10000 inch)
		Top Deck Waviness	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing (1)
3500E Block	456-6312	Top Deck Surface Texture	2.5 µm (98.43 µinch) Ra Roughness Sampling Length or Cutoff - 2.54 mm (0.10000 inch) Average Roughness Peak to Valley Height - 19.0 µm (748.03 µinch) Rz
		Top Deck Waviness	Minimum Waviness Height - 0.0125 mm (0.00049 inch) per 5.0 mm (0.20 inch) of spacing(1)

(1)	For waviness spacing smaller than 5.0 mm (0.20 inch) use maximum waviness height of 0.00254 PER mm (0.00010 PER inch) spacing.

Top Deck (Angle) Specification

The specification of angle (H) of the top deck must be maintained. The specification of the flatness (G) of the top deck must be maintained. The surface of the machined deck must meet two requirements for this specification.

Illustration 6	g01393964
Angle of the top surface of the deck. (D) Distance from the center line of crankshaft bore to the surface of top deck (6) Horizontal center line of crankshaft bore (7) Parallel plane that must contain the surface of the top deck (8) Surface of the top deck

1. The surface must not be machined to less than the minimum specified distance (D) from the center line of the crankshaft bore.

2. The angle of the surface must be within two parallel planes that are separated by 0.13 mm (0.005 inch). The machined surface must fall within these parallel planes. The machined surface must be within the maximum and minimum tolerances for the dimension (D).

Lengths of Blocks Specification

Refer to Table 6 for length dimensions of the cylinder blocks and Illustrations 7 and 8 for examples.

The length of the cylinder block is measured from the front thrust face to the ends of the cylinder blocks. The 3508, 3512, 3516 cylinder blocks are measured from front of the thrust face to the respective side of the cylinder block. The G3520 cylinder block is measured from the rear thrust face to each end of the cylinder block.

Illustration 7	g06181008
3508, 3512, 3516 Cylinder Blocks

Illustration 8	g06181011
G3520 Cylinder Block

Table 6

Cylinder Block Lengths and End Face Surface Texture
Engine Model	Dimension	Description	Value
3508	A	Thrust face to front face of block	576 ± 0.2 mm (22.7 ± 0.010 inch)
	B	Thrust face to rear face of block	624 ± 0.2 mm (24.570 ± 0.010 inch)
3512	A	Thrust face to front face of block	846 ± 0.2 mm (33.3 ± 0.010 inch)
	B	Thrust face to rear face of block	894 ± 0.2 mm (35.197 ± 0.010 inch)
3516	A	Thrust face to front face of block	1116 ± 0.2 mm (43.937 ± 0.010 inch)
	B	Thrust face to rear face of block	1164 ± 0.2 mm (45.827 ± 0.010 inch)
G3520	C	Thrust face to rear face of block	4.5 ± 0.2 mm (0.178 ± 0.010 inch)
	D	Thrust face to front face of block	2810.5 ± 0.2 mm (110.650 ± 0.010 inch)
Surface Flatness of Block Ends			0.08 mm (0.003 inch)
Surface Texture of Block Ends			Ra = 3.2 µm (125.98 µinch) or better
Runout to the Crank Axis			0.1 mm (0.004 inch)

Visual Inspection

Damage of the Cylinder Block

Cracking

Cylinder blocks with cracks on the top deck surface under the liner flange can be repaired with metal spray or inserts. Cracking that extends from a coolant passage or from a bolt hole into the cylinder block bore cannot be salvaged.

Illustration 9	g01393786
Cracks extend from bolt holes (1) and coolant passages (2) into the bore of the cylinder block. Do not use the block again.

Coolant Passage Pitting

Pitting of the cylinder block near the coolant passages or under the liner seat can result in external coolant leaks.

Illustration 10	g01393798
Damage from pitting (3) around the coolant passages

If the pitting is deeper than 0.13 mm (0.005 inch) or if the pitting has occurred completely around the coolant passage, then repair the pitting by using one of the following methods.

Cylinder Block Pitting Near the Upper Liner Seal

Illustration 11	g06181013
Example of pitting as it relates to the Upper Liner Seal. (1) Liner cross section (2) Cylinder Block (3) Upper Liner Seal cross section (4) Pitting

In some conditions, pitting can develop in the cylinder block liner bores near the bottom edge of Upper Liner Seal (3). If pitting in the upper bore is discovered, then the location and severity must be considered when assessing repair options.

Pitting discovered in this area of the block does not necessarily need to be salvaged. Pitting can vary in location and severity. Usually the pitting is cosmetic in nature and the cylinder block can be reused without durability concerns.

Note: Pitting measurements are not exact dimensions and measuring the pitting severity with a high degree of precision is not necessary. A liner bore inspection tool or calipers are sufficient for measuring from the top deck. A visual estimation is adequate for determining pitting depth. Refer to Figure 78 for the Liner Bore Inspection Tool print specifications.

Generally, pitting within 4.5 mm (0.17 inch) from the top deck and/or 0.5 mm (0.02 inch) in depth or deeper will need to be repaired. The measurement 4.5 mm (0.17 inch)is an approximate dimension measure from the block deck surface.

Illustration 12	g06046430
Inspection Tool

Illustration 13	g06053709
(5) Sealing Region (less than 4.5 mm from the top deck): (6) Non-Sealing Region (more than 4.5 mm from the block deck)

1. Non-Sealing Region (more than 4.5 mm from the block deck):
   Pitting in the non-sealing region will not interfere with the Upper Liner Seal performance. Salvage is not required for pitting in this region unless the pitting is severe. Usually, the cylinder block can be cleaned and reused.

2. Sealing Region (less than 4.5 mm from the top deck):
   Pitting may be within or under the sealing surface for the Upper Liner Seal. If the pitting severity is minimal, then the cylinder block may still be reused without performing a salvage procedure.

Note: Prudence and sound technical judgment is required when deciding between direct reuse of the block and salvage of the block. Currently, block inserting is the best salvage option available. Dealers must consider their own experience and aptitude for inserting when considering salvaging the cylinder block.

Illustration 14	g06024328
Example of moderate to severe pitting that approaches liner bore chamfer. (A) 4.5 mm (0.17 inch)

Pitting as shown in Illustration 14 ranges from moderate on the left to severe on the right. The pitting on the left is within the 4.5 mm (0.17 inch) sealing region and begins to approach the liner bore chamfer on the right. The combination of severe pitting on the right and the proximity to the chamfer would require this example to be salvaged.

Illustration 15	g06181019
Examples of pitting severity. (7) Severe Pitting: Salvage repair needed (8) Moderate Pitting: Salvage repair needed. (9) Minimal Pitting: Salvage repair not needed.

Illustration 15 highlights the range of liner bore pitting. In all three examples the pitting was greater than the 4.5 mm (0.17 inch) guidance. However, Example (3) of Illustration 15 must be salvaged due to the severity of the pitting.

Pitting depth into the cylinder block liner bore can be difficult to measure and analyze. Sound technical judgment is required when determining the severity of the pitting. If pitting depth is minimal and does not affect areas that are likely to compromise the Upper Liner Seal performance, then direct reuse of the block may be possible. If the pitting depth is severe, or the affected area is large enough to compromise the Upper Liner Seal performance, then salvage procedures may be required.

Due to the case-by case, subjective nature of inspecting and assessing pitting near the upper liner seal, numerous visual examples have been provided to serve as references. Photos are grouped by severity, notable facts are presented, and reuse or salvage recommendations are offered. However, the final assessment of severity and conclusion regarding reuse or salvage remains with the dealership.

The following are three examples of minimal pitting. These photographs are examples that do not need to be salvaged.

Illustration 16	g06181020
Minimal pitting depth. Pitting in non-sealing region around entire bore. Reuse

Illustration 17	g06181021
Minimal pitting depth. Pitting in non-sealing region in few locations around liner bore. Reuse

Illustration 18	g06181023
Minimal pitting depth. Pitting in non-sealing region and in few locations around liner bore. Reuse

The following are three examples of moderate pitting. These examples demonstrate situations that would be more difficult to determine the need to salvage due to their subjective wear. Prudence and sound technical judgment is required when deciding between direct reuse of the block and salvage of the block.

Illustration 19	g06052840
Moderate pitting depth. Pitting in non-sealing region and continuous around liner bore. Reuse

Illustration 20	g06052868
Moderate pitting depth. Pitting on edge of sealing region and continuous around liner bore. Salvage

Illustration 21	g06052878
Moderate pitting depth. Pitting in both sealing and non-sealing region and continuous around entire liner bore. Salvage

The following of severe pitting illustrate damage that is more visually obvious. Usually of such severe pitting, salvage would be required.

Illustration 22	g06052889
Severe pitting depth. Pitting in non-sealing region and continuous around liner bore. Salvage

Illustration 23	g06052918
Severe pitting depth. Pitting in sealing region and continuous around liner bore. Salvage

Illustration 24	g06052930
Severe, spotted pitting depth. Pitting within sealing region and continuous around liner bore. Salvage

Cylinder Block Top Deck Salvage Options for 3500 Engines

This section contains the procedures to repair top deck damage on 3500 cylinder blocks and the threaded holes in the top deck of cylinder blocks. The threaded holes can be damaged during an engine rebuild. Damaged threads can cause improper torque of the head bolts, resulting in possible failure. Using this threaded insert repair procedure, bolt holes can be repaired to "like new" condition. Use this guideline as the only source of reference when installing the Kent- Moore® threaded insert.

To repair stripped or cracked head bolt holes, use the PT-2801 Porta-Thread Basic Kit, with the PT-2801-3 Service Kit. A thin-wall solid steel insert with a sealed bottom prevents coolant leakage from the cylinder head bolt holes. This insert can often repair cracked blocks that, until now, would be scrapped.

Cylinder block repair is made easy using a base plate and drill jig to maintain perfect alignment during reaming and tapping operations.

Top Deck Threaded Hole Repair

Nomenclature

Illustration 25	g02119154
Basic Kit (PT-2801) (1) PT-7270 Loctite Compound (50 cc) (2) PT-7260 Loctite Primer T [ 178 mL (6 oz)] (3) PT-2900-6 Super Chip Vacuum and PT-2900-2 90 Degrees Extension (4) RS-13300-250 Washer (5/8 in SAE) (5) RS-9103-100 Hex Head Bolt (5/8-18 x 3 in, Grade 5) (6) PT-2800-32 Drill Jig (7) PT-2800-33 Base Plate (8) RS-15100-175 Allen Wrench (1/8 in) (9) PT-1000-20 Universal Drive (A) J-34970 Storage Box (not shown) (B) PT-2801-22 Foam Insert (not shown)

Illustration 26	g06304381
Service Kit (PT-2801-3) (10) PT-2800-24 Stud Adapter (11) PT-2800-30 Installing Nut (12) PT-2800-26 Stop Collar Assembly (13) PT-2800-41 Installing Bolt (14) RS-13-300 Washer (7/8 in SAE) (15) PT-2800-29 Locating Pin (16) PT-2800-38 Special Reamer (17) PT-2800-39 Special Tap (C) PT-2800-40 Spacer (not shown)

Repair Procedure

Use the following procedure to carry out repair operation:

1. File the top deck to remove all burrs and high spots. Thoroughly clean the area for proper tool location.

2. Attach the drill jig (6) to the base plate (7) using the hex head bolt (5) and the washer (4). Place the drill jig on the cylinder block, aligning the base plate over two holes across from each other. Use the cylinder head bolts, washers, and the stud adapters (10) to secure the base plate (7) to the cylinder block. Torque the bolts to 41 N·m (30 lb ft).

3. Loosen the hex head bolt (5) and position the drill jig (6) over the hole to be repaired. Insert the locating pin (15) through the drill bushing and into the bolt hole. Tighten the bolt (5) to 40 N·m (30 lb ft) and remove the locating pin. Refer to Illustration 27.

4. Insert special reamer (16) through drill bushing into top of bolt hole.

5. Install the universal drive (9) in the chuck of an electric drill (slow speed drill is best) and begin reaming the damaged bolt hole. Stop after reaming to a depth of about one in. Refer to Illustration 27

6. Remove the reamer and clean out shavings with a chip removing unit. Continue reaming to the bottom of the hole. Remove the reamer and thoroughly clean out all shavings from hole.
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   NOTICE
   To avoid damage to the tooling, keep the reamer shank and drill bushing free of metal shavings.

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   Illustration 27	g06304389
   Position drill jig (6) over damaged bolt hole.

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   Illustration 28	g06304392
   Insert tap. (18) Threaded insert.

7. Insert the special tap (17) through the drill bushing, allowing it to set on top of the hole. Using a threaded insert (18), adjust the depth stop collar (12) on tap, as shown in the Illustration 28.
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   Illustration 29	g06304394
   Tap the hole.

8. Using a low speed drill or tap handle, tap the hole. If using a drill, stop when there is a 3.0 mm (0.12 inch) gap between the stop collar and guide bushing. Finish tapping the hole by hand.
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   Illustration 30	g06304396
   Remove all debris from hole using the chip vacuum or compressed air.

9. Remove the tap and the drill jig fixture from the cylinder block. Clean the hole thoroughly with a chip removing unit.
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   Illustration 31	g06304397
   Attach installing bolt (13) to threaded insert and install insert. (11) PT-2800-30 Installing Nut (13) PT-2800-41 Installing Bolt (18) Threaded insert.

10. Thread the special installing nut (11) onto a cylinder head bolt or installing bolt (13). Install the nut to end of threads, then back off the nut about 1/4 turn.

11. Screw threaded insert onto installing bolt (or head bolt, if used) until it touches the nut. Clean the outside diameter threads of the insert with 4C-9500 Quick Cure Primer (2). Let dry, then coat with 9S-3263 Thread Lock Compound (1). Using a wrench on the installing bolt, screw the threaded insert into the block until installing nut bottoms on top of block.

12. With another wrench, hold the bolt and loosen the nut from the threaded insert, then remove the bolt.

Illustration 32	g06304400
Remove installing bolt (13).

Reconditioning the Cylinder Block

The following table will help direct what type of rework is needed on 3500 Engine Blocks.

Table 7

Block Top Deck Location	Defect Type	Defect Inspection	Defect Limits	Rework Type
Under the Liner Flange	Wear (1)	8T-0455 Liner Projection Tool Group	Depth < 0.013 mm (0.0005 inch)	No Rework Required
			Depth ≥ 0.013 mm (0.0005 inch)	Surface Remilling
				Twin Wire Arc Spray (TWAS)
				Stainless Steel Insert
	Pitting	Visual 8T-0455 Liner Projection Tool Group Profilometer/Surface Texture Gauge	No Pitting Allowed	Surface Remilling
				TWAS
				Insert
	Cracks	Visual Magnaflux Dye Penetrant	No Cracks Allowed	Insert
In Liner Bore	Pitting	Visual Caliper Liner Bore Inspection Tool(2)	From top deck ≥ 4.5 mm (0.17 inch)and/or minimal pitting	No Rework Required
		Caliper Liner Bore Inspection Tool	From top deck < 4.5 mm (0.17 inch)and/or severe pitting	Insert
Water Ferrule Sealing Areas and Gasket Sealing Areas	Pitting	Visual 8T-0455 Liner Projection Tool Group Profilometer/Surface Texture Gauge	Depth < 0.13 mm (0.005 inch)	No Rework Required(3)
			Depth ≥ 0.13 mm (0.005 inch) or completely around the cooling passage. (4)	Surface Remilling
				TWAS
				SS Insert
				Belzona® 1311 (Ceramic R Metal)
Between Water Ferrule and Liner Flange	Pitting	Visual 8T-0455 Liner Projection Tool Group	Pitting smaller than 0.8 mm (0.03 inch) acceptable	No Rework Required

(1)	Wear step created by fretting under the liner flange
(2)	Refer to Figure 78 for tool print specifications.
(3)	If surface meets surface texture requirements to ensure water ferrule sealing.
(4)	Max-Defined by rework type

It is critical to maintain the correct compression ratio of 3500 Engines during reconditioning. Do not exceed the minimum specifications of top deck height. The ratio is increased as material is removed from the surface of the cylinder head and block. If machining alone is not able to remove all the damage, then arc spray (TWAS) can be performed.

Twin Wire Arc Spray is the Caterpillar recommended block salvage method. Applied properly, arc spray can salvage the engine block to original parent material specifications with the added benefit of increased corrosion resistance. The increased corrosion resistance that arc spray provides will help reduce future repair needs.

Removal of Material

Machining the top deck of the cylinder block is the preferred method of repair when damage is small. When machining is done on the top deck of the cylinder block, remove the minimum amount of material that is necessary to remove the damage. Refer to Table 4 for reconditioning specifications.

Top Deck Inserts

Light machining of the top deck and/or arc spray is the preferred repair options for Cat engine blocks. If metal spray capabilities are not available, then inserting the top deck is an acceptable practice. The top deck can be inserted in the water ferrule and liner bore locations.

Belzona® 1311 (Ceramic R Metal) as an Alternate Field Repair Option

Illustration 33	g02602356

A cylinder block with minor pitting near the smaller water seals can also be repaired with Belzona® 1311 (Ceramic R Metal).

Note: The following areas must be covered or plugged during the repair: cylinder bore, inlet port, exhaust port, and cylinder head bolt openings. These areas could become contaminated if not properly protected.

1. Use a ¾ inch drill bit to remove only enough metal to remove the porous material. The depth of the cut should not exceed ¼ inch. The water port opening is the pilot on the small seal.
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   Illustration 34	g06304429

2. Grind an undercut around the middle of the ¾ inch water port opening, using a die grinder with a cutoff wheel dressed to fit the opening.

3. Sweat the area to be repaired. This can be accomplished by using a propane or acetylene torch. Little heat is required. This will remove the oil and moisture from the casting.

   Note: Caution must be used to prevent the damaging of other seals, gaskets, and components in the area.

4. Clean the prepared area with Belzona® 1311 (Ceramic R Metal) cleaner. The Belzona® 1311 (Ceramic R Metal) cleaner will dry and leave no film residue.

5. To maintain the proper water port diameter a ½ inch diameter by 3 inch long wooden dowel rod will be installed in the water port opening. Before the rod is installed coat the rod with Belzona® 1311 (Ceramic R Metal) release agent and let dry.

6. Mix the Belzona® 1311 (Ceramic R Metal) material per package instructions.

   Note: Do not contaminate the product during mixing. Use a separate measuring devices or thoroughly clean between the measuring of the two different agents.

7. Wet the area to be repaired. Apply small amounts of the Belzona® 1311 (Ceramic R Metal) with a small flat stick. Work the Belzona® 1311 (Ceramic R Metal) into the undercut. Make sure that all areas are wet.

8. Install the ½ inch dowel into the water port. This is after the release agent has been applied to the dowel and has dried.

9. After the dowel is in position continue applying the Belzona® 1311 (Ceramic R Metal) until the drilled area is slightly higher than the top deck of the block.

10. After approximately 30 minutes from the original mix time, the applied material can be smoothed. Be sure to wear rubber gloves and check to see if the surface of the repair material has a dried film, or is sticky.

11. If the repair material sticks to the finger of the glove, it is still too wet. To get a smooth finish for the material at the repaired area, dip the fingers of the gloves in water, and work the surface back and forth. Use only enough water to wet the fingers. Too much water on the Belzona® 1311 (Ceramic R Metal) repair material can have adverse effect on its mechanical strength.

12. Press firmly to force out any time that may have been trapped in the material during the smoothing process. If this smoothing procedure is done correctly, it will reduce the time needed for sanding once the Belzona® 1311 (Ceramic R Metal) repair material has cured.

13. Belzona® 1311 (Ceramic R Metal) repair material can be removed from non-repair areas using theBelzona® 1311 (Ceramic R Metal) cleaner before the Belzona® 1311 (Ceramic R Metal) hardens.

14. Approximately two to three hours after the Belzona® 1311 (Ceramic R Metal) has been applied, it should be hard enough for sanding. Remove the excess material and sand flush with the top deck of the cylinder block. Be careful not to dish the repaired area.

    Note: Curing time. When the Belzona® 1311 (Ceramic R Metal) is mixed and used at a temperature of 21° C (70° F), it will develop its full mechanical capabilities in 24 hours

Procedure to Repair the Top Deck with Water Ferrule Inserts

3500 cylinder blocks with pitting around the water passages can be repaired with stainless steel inserts.

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NOTICE
Water ferrule inserts must be installed prior to the liner seat insert counter-bore being cut. If the water ferrule inserts are installed after the counter-bore is cut, then the counter-bore will distort.

Do not use oversized diameter water ferrule inserts. Water ferrule inserts must not come into contact with liner seat inserts. There must be parent block material remaining between the water ferrule and the liner bore inserts.

Illustration 35	g02602016
(1) pitting around water passages

Illustration 36	g03546077
Pitting in the yellow area does not need repair. If the surface meets surface texture requirements to ensure water ferrule sealing, then pitting between the water passage and the liner seat are acceptable.

Water Ferrule Inserts

Table 8

Water Ferrule Inserts
Part No.	Description	Outer Diameter
417-3778	(Small Insert)	20.671 ± 0.006 mm (0.8138 ± 0.0002 inch)
417-3779	(Large Insert)	30.205 ± 0.006 mm (1.1892 ± 0.0002 inch)

Driver adapters for the water ferrule inserts can be fabricated to ease the installation of the inserts. The drivers should be small enough so that the driver does not totally cover the insert. This will allow better visual alignment of the insert when the insert is installed into the block.

The driver adapter for the smaller insert should have a shoulder that fits inside the hole in the middle of the water ferrule insert. The driver adapter for the larger insert should have a counter-bore for the bolt head that holds the adapter onto the driver handle. This adapter will allow the driver adapter to sit flush on top of the larger water ferrule insert.

The following illustration and table lists approximate dimensions for the driver adapters.

Illustration 37	g06181032
(1) Fabricated driver for small water ferrule inserts (2) Fabricated driver for large water ferrule inserts

Table 9

Callout	Dimension
A	19 mm (0.75 inch)
B	Passage for bolt
C	10 mm (0.40 inch)
D	28 mm (1.10 inch)
E	Counter-bore for bolt head

Water Ferrule Insert Repair Procedure

1. Clamp the cylinder block in place.
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   Illustration 38	g02602276
   A template refers to Illustration 77 for fabrication specifications.

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   Illustration 39	g03842018
   Dimensions for counter-bore Refer to Illustration 10 for specifications. (F) Counter-bore diameter (G) Counter-bore depth (H) Counter-bore radius

2. Use an end mill to machine a counter-bore in the water passage. The end mill that is used on the small counter-bore should be 20.637 ± 0.013 mm (0.8125 ± 0.0005 inch). The end mill that is used on the large counter-bore should be 30.162 ± 0.013 mm (1.1875 ± 0.0005 inch). Refer to Table 10 and Table 11 for the dimensions of the counter-bore.

   If the top deck is not machined after insert installation, then the insert thickness must be measured and the counter-bore depth adjusted. The counter-bore depth must be cut such that the final water ferrule insert projection is within ± 0.052 mm (0.002 inch).

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   Table 10

   Dimensions for the Small counter-bore in the Coolant Passage(1)
   Diameter (F)	20.637 ± 0.013 mm (0.8125 ± 0.0005 inch)
   Radius (H)	0.63 ± 0.13 mm (0.0250 ± 0.005 inch)
   Depth (G)(2)	5.000 ± 0.250 mm (0.1969 ± 0.0098 inch)

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   (1)	Refer to Illustration 39
   (2)	If top deck machining is not performed, then depth can be adjusted. Refer to Step 2 above.

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   Table 11

   Dimensions for the Large counter-bore in the Coolant Passage
   Diameter (F)	30.162 ± 0.013 mm (1.1875 ± 0.0005 inch)
   Depth (G)(1)	5.000 ± 0.250 mm (0.1969 ± 0.0098 inch)

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   (1)	If top deck machining is not performed, then depth can be adjusted. Refer to Step 2 above.

3. Deburr the corner of the counter-bore and use isopropyl alcohol to clean the counter-bore and to clean the inserts. A clean, lint free cloth should be used to clean any machining residue from the counter-bores and the inserts.

   Note: The radius on the outer diameter of the insert should be toward the cylinder block.

4. To ensure that the insert is pressed fully into the coolant passage, measure the counter-bore depth and insert thickness. The difference should result in a uniform insert projection of 0.02540 mm (0.001 inch)

5. Apply Loctite 640 to the counter-bore on the outside edges and seating surface sufficiently to create a continuous seal.

   Excessive Loctite may make the final insert projection hard to achieve. If the insert is not seated within 10 minutes of the applying the Loctite, the Loctite can begin to set up keeping the insert from properly seating. The Loctite will need to be removed and the install process must be started from the beginning.

6. Start installation of the insert by hand into the counter-bore.
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   Illustration 40	g02602319

7. Drive the insert into the counter-bore of the coolant passage using 441-3674 Water Ferrule Driver.

8. For the large insert ensure that the water feed holes do not overlap after the press fit.

9. Verify that the inserts are properly seated and sealed by performing a leak test.

Illustration 41	g02602326
An example of an insert pressed into a cylinder block.

Procedure to Leak Test the Water Ferrule Inserts

Loctite must be allowed to cure for a minimum of six hours from the time the last insert was pressed in place prior to leak testing. If the top deck will be machined, then the leak test must be conducted before and after machining.

1. Use the 434-6509 Insert Leak Test tool.

2. Apply 207 kPa (30 psi) to the leak test tool.

3. Spray soapy water on the seam where the insert and deck face meet. Spray the entire circumference of the insert.

4. Inspect for bubbles around the outer diameter of the insert seam on the block face.

   If bubbles are present, then remove the insert and investigate the root cause. Do not reuse the removed insert.

3500 Sealed Insert

This section contains the procedures to install liner seat inserts in the cylinder blocks of 3500 Engines. See Table 7 for recommended repair options.

Salvaging the 3500 engine block can be accomplished by removing damaged material and replacing the material with a sealed insert. The sealed insert is a more robust repair option than a non-sealed insert. The sealed insert design has critical advantages over the non-sealed insert design.

The sealed insert has a metal shim with an integral seal. The integral seal provides a rubber face seal to prevent coolant leaks from occurring around the insert. Tighter press fit on the insert eliminates the need for any bonding adhesive. The inserts are backwards compatible. If the block being salvaged was inserted in the past, then one of the inserts available will be applicable.

The liner seat inserts are made from stainless steel that provide corrosion resistance. Inserts that are made from other materials are less resistant against fretting or corrosion.

Cylinder blocks that do not require an insert must have the top edge of the liner bore chamfered to accept the 352-6061 Liner Seal. The chamfer is needed to install the 352-6061 Liner Seal properly. The 353-5617 Insert and 353-5618 Insert include a machined chamfer to accept the 352-6061 Liner Seal. Refer to the "Procedure to Chamfer Liner Bores" section within this document for the procedure used to machine the chamfer.

If the 5P-4175 Counter-boring Tool Group is used to machine the counter-bore, refer to the " 5P-4175 Counterboring Tool Group" section of this guideline for instructions to use and adjust the tool group.

Note: Do not coat the 352-6061 Liner Seal in engine oil for installation. 5N-5561 Silicone Lubricant or 186-1528 Silicone Lubricant is used for lubrication. Refer to the appropriate Disassembly and Assembly manual for additional assembly instructions.

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NOTICE
Water ferrule inserts must be installed prior to the liner seat insert counter-bore being cut. If the water ferrule inserts are installed after the counter-bore is cut, then the counter-bore will distort.

Illustration 42	g03818628
Illustration of sealed insert

There are two insert diameter sizes available and both use the same integral sealed shim.

(A) Insert

(B) Integral Seal

The procedure to install the sealed insert involves counterboring the liner bore, cleaning the counter-bore, installing the shim and insert, machining the liner bore and machining the top deck.

1. Determine the size of the insert needed is standard or oversized. Blocks that have been salvaged previously with the standard-size insert, can be salvaged with the 473-0494 Insert Kit (Oversize) inserts.
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   Table 12

   Previously Inserted Integral Seal Insert and Non-Sealed Insert Cross Reference
   Insert Part Number	Outside Diameter	Serviced Using Sealed Inserts	Process
   NA(1)	NA	473-0493	Machine counter-bore to correct depth and diameter. Refer to Table 13
   353-5617	212.115 mm (8.3510 inch)	Yes 473-0494	Machine counter-bore to correct depth and diameter. Refer to Table 13
   353-5618	212.115 mm (8.3510 inch)	Yes 473-0494	Machine counter-bore to correct diameter. Refer to Table 13
   335-8971	212.370 mm (8.3610 inch)	Yes(2) 473-0494	Inspect counter-bore for proper size and reuse counter-bore if possible.Refer to Table 13-

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   (1)	Never previously inserted blocks.
   (2)	If no additional machine work needs to be performed.

2. Freeze the inserts to aid in installation.

   Note: Freeze the insert only, not the integral seal. A temperature difference of 90° C (195° F) between the block and the insert will aid in installation to allow an easier slip fit of the insert into the counter-bore.

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   Illustration 43	g03817062
   counter-bored 3500 cylinder block

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   Illustration 44	g06181051
   Cross section of counter-bore (A) Counter-bore Diameter (B) Counter-bore Depth (C) 0.8 mm (0.0312 inch) Radius

3. Counter-bore the liner bore.

   Counter-bore the liner bore to the specifications given in Illustration 44 and Table 13. Ensure that the surface texture for the counter-bore is kept at Ra 3.2 µm (125.98 µinch).

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   Table 13

   Integral Seal Counter-Bore Dimensions
   Part Number	Counter-bore Diameter (A)	Counter-bore Depth (B)(1)
   473-0493 Insert Kit (Standard)	211.989 ± 0.025 mm (8.3460 ± 0.0010 inch)	7.620 ± 0.025 mm (0.3000 ± 0.0010 inch)
   473-0494 Insert Kit (Oversize)	212.238 ± 0.025 mm (8.35581 ± 0.00098 inch)	7.620 ± 0.025 mm (0.3000 ± 0.0010 inch)

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   (1)	The precise counter-bore depth can be calculated by combining the measured thickness of the insert and the thickness of the metal portion of the integral seal.

4. Clean the bore and deburr counter-bore. Remove any metal shavings from the counter-bore area and use isopropyl alcohol to remove any oil or dirt residue.
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   Illustration 45	g03817069
   Integrated seal installed.

5. Place the 433-4929 Integral Seal into the counter-bore.

6. Retrieve the frozen insert from the freezer and set onto the counter-bore.
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   Illustration 46	g03817087

7. Use appropriate tooling, orient the tooling onto the insert, and finger tighten the bolts.
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   Illustration 47	g03817118
   Install tooling will not contact the block face

8. Use an impact or socket driver with a crossing pattern tighten the four bolts evenly to press the insert squarely into the counter-bore. Torque the four bolts to 200 N·m (150 lb ft)

   Note: The tooling will sit proud of the block when fully pressed in. This design is to concentrate the installation force onto the insert and to allow room for water ferrule inserts.

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   Illustration 48	g03817098
   Inspect insert projection with tooling in place.

9. Leave the tooling in place, use the liner projection tooling to measure insert projection in the notches of the tooling. The tooling applies pressure on top of the insert to replicate the cylinder head onto the liner.

10. When all inserts have been installed, bore the inside diameter of the insert to be flush with the liner bore.

11. Mill inserts flush with the top deck of the cylinder block.

12. Reinstall the tooling and using the liner projection tooling check insert projection again for each bore. This inspection ensures that the inserts have not shifted during the milling process.

Inserts installed in the field can be installed such that the insert does not require machining of the top deck. Field installation requires measuring the deck height to verify the depth of the counter-bore.

Machining of the top deck is recommended when the entire block is being salvaged. Machining the top deck ensures that the projection of the insert is within the correct specifications.

Machining the top deck has the following advantages:

• Machining ensures that the correct flatness and insert projection are obtained.

• Machining simplifies the salvage process by not requiring a tighter tolerance control and liner projection measurement.

• Machining removes pitting from the water ferrules and the liner flange which may be necessary.

Leak Test

If the top deck will be machined, the leak test must be conducted before and after machining.

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Illustration 49	g06181057

1. Install the 373-5840 leak test tool in the bore.

2. Connect an air hose and apply 206.8 kPa (30.00 psi) to the leak test tool.

3. Spray soapy water on the deck where the liner insert and the deck face meet. Spray the entire circumference of the insert.

4. Inspect for bubbles around the outer diameter of the insert on the block face. If no bubbles are observed, repeat the test for the next cylinder.

If bubbles are present, remove the insert and investigate the root cause.

Procedure to Chamfer Liner Bores

If the cylinder block does not have a liner bore chamfer, does not require liner seat inserts, or has previously had installed non-chamfered stainless steel liner bore inserts, then the top deck edge of the bore for the liner must be chamfered to accommodate the 352-6061 Liner Seal.

Machining Process

Illustration 50	g02603916
(1) Cutter

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NOTICE
Cut the chamfer on the largest bore first. Locating the tool on the largest bore first will minimize the possibility of having to readjust the tooling and ensure that a uniform liner flange mounting surface is maintained.

Note: Cleanliness of the upper liner bore is critical to ensure a proper cut.

1. Thoroughly clean the block deck face and upper liner bore before locating the cutter body and tool.

2. Check the diameter of the bore for out of roundness. The diameter of the upper liner bore is 199.000 + 0.040 mm - 0.025 mm (7.8346 + 0.0016 inch - 0.0010 inch). A distorted bore cannot be chamfered.

3. Locate the tool at the bore. The plate should slide into the bore when located properly.

4. Clamp the tool to the block. Tighten the bolts slowly and evenly to prevent the plate from becoming cocked in the bore. The bolts should be tightened to 80.0 N·m (60.00 lb ft).

5. Retract the holder from the bore and install the cutter so that the edge with the angle will intersect the top corner of the liner bore and the block deck face. When tightened, the cutter body will spin free.
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   Illustration 51	g02603921
   (2) spacer

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   Illustration 52	g06181092
   Example of optimal starting position. (1) Cutter

6. Touch the cutting edge of the cutting tool off the corner of the upper liner bore and the block deck face. Use a 2.00 ± 0.20 mm (0.079 ± 0.008 inch) shim or spacer (2) between the depth adjusting nut in place. Remove the 2.00 ± 0.20 mm (0.079 ± 0.008 inch) shim or spacer (2) from tool once depth is set.

   Note: When setting the cutting tool off the edge of the liner bore, allow for 2.00 ± 0.20 mm (0.079 ± 0.008 inch) of vertical travel.

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   Illustration 53	g02604016

7. Use a drill to run the tool until the tool reaches the present depth.

Note: Deburr any sharp edges. Use the 365-1197 Liner Brush to deburr the upper and lower edge.

Illustration 54	g06181095
(D) Angle of the chamfer (E) Depth of the chamfer

Table 14

Chamfer Dimensions
(D)	11° ± 1°
(E)	2.00 ± 0.20 mm (0.079 ± 0.008 inch)

Illustration 55	g02604097
Finished chamfer

Inspect the entire chamfer to ensure a uniform cut around the circumference of the bore. The chamfer should maintain the proper depth around the circumference. If the chamfer is not even, the tool should be reset and the chamfer should be cut again.

Note: There is no difference in performance or reliability between a straight chamfer and the counter-bore found on the 353-5617 Insert, the 353-5618 Inserts, and the 335-8971 Insert. The counter-bore is used on the 353-5617 Insert, the 353-5618 Insert, and the 335-8971 Insert for mass production purposes.

Cylinder Block Lower Liner Bore Salvage Procedure for 3500 Engines

Summary

This section gives two methods that are used to salvage the cylinder block liner bores on 3500 Engines. The first method uses a process that is known as step bore operation. A step, which is part of the cylinder block casting, is created by machining an oversized bore in the cylinder block casting to a specified depth. A sleeve is then inserted into the oversize bore and pressed against the step. The remaining step provides a positive stop and ensures a good seal. The second method machines the oversize bore completely through the block with no step. The sleeve is then retained by screws that are threaded into the sleeve and the cylinder block casting. The second method involves machining an oversized bore in the block casting to accept a fabricated sleeve. Two blind holes are drilled and tapped through the block and into the sleeve.

Nomenclature

Illustration 56	g06181097
Sleeve and Step Method of salvage (1) Block (2) Sleeve

Illustration 57	g01919894
Sleeve and Pin Method of salvage (1) Block (2) Sleeve (3) Screw (pin)

Salvage of the Lower Liner Bore

Step Method

Note: Sleeves are not available through Caterpillar for this salvage procedure. Sleeves must be machined prior to the salvage operation with the specifications in Illustration 58 and Table 15.

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Illustration 58	g01926778
Machine the sleeve for the salvage procedure. Refer to Table 15 for dimensions.

1. Use general-purpose gray iron casting and machine the necessary number of sleeves for the salvage operation.

   Note: Size the sleeve and the bore to produce a 0.20 ± 0.05 mm (0.008 ± 0.002 inch) press fit.

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   Table 15

   Dimensions for Machining the Sleeve
   Item	Dimension
   (A)	36.00 mm (1.420 inch)
   (B)	2.54 mm (0.100 inch)
   (C)	197.83 mm (7.789 inch)
   (D)	0.80 mm × 45° (0.030 in × 45°)

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   Illustration 59	g06181102
   Machine the bore to specified dimensions. (E) 197.83 ± 0.12 mm (7.789 ± 0.005 inch) diameter (F) 3.00 mm (0.118 inch) step.

2. Bore the block to 197.83 ± 0.12 mm (7.789 ± 0.005 inch) diameter (E). Leave a 3.00 mm (0.118 inch) step (F) at the bottom of the bore. Refer to Illustration 59.

3. Clean the bore and the sleeve with 4C-9500 Quick Cure Primer. Apply 4C-9507 Retaining Compound only to the bore.

4. Shrink the sleeve by freezing to ease inserting the sleeve and obtain the press fit. Install the sleeve and hold the sleeve in place until the sleeve is seated. Allow at least an hour for the Retaining Compound to cure before finish machining.

5. Finish machining inside of the sleeve to 193.65 ± 0.05 mm (7.624 ± 0.002 inch).
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   Illustration 60	g06181106
   Cross section of liner bore showing sleeve chamfer.

6. Chamfer the top of the sleeve 60°.

Pin Method

Note: Sleeves are not available through Caterpillar for this salvage procedure. Sleeves must be machined prior to the salvage operation with the specifications in Illustration 61 and Table 16.

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Illustration 61	g01927653
Machine the sleeve for the salvage procedure. Refer to Table 16 for dimensions.

1. Use general-purpose gray iron casting and machine the necessary number of sleeves for the salvage operation.

   Note: Size the sleeve and the bore to produce a 0.20 ± 0.05 mm (0.008 ± 0.002 inch) press fit.

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   Table 16

   Machining Dimensions for the Sleeve
   Item	Dimensions
   (G)	42.00 mm (1.650 inch)
   (H)	4.06 mm (0.160 inch)
   (J)	201.00 mm (7.913 inch)
   (K)	0.80 mm × 45° (0.030 in × 45°)

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   Illustration 62	g01927673
   Machine the bore to specified dimensions. (L) 201.00 ± 0.12 mm (7.913 ± 0.005 inch) diameter

2. Bore the block to 201.00 ± 0.12 mm (7.913 ± 0.005 inch) diameter (L).

3. Clean the bore and the sleeve with 4C-9500 Quick Cure Primer. Apply 4C-9507 Retaining Compound only to the bore.
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   Illustration 63	g01927674
   Install the sleeve.

4. Shrink the sleeve by freezing to insert the sleeve and obtain the press fit. Install the sleeve so that the top surface of the sleeve is flush with the inner surface of the block. Hold the sleeve in place until the sleeve is seated. Allow at least an hour for the Retaining Compound to cure before finish machining.

5. Finish machining the sleeve so that the sleeve is flush with the bottom of the bore.
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   Illustration 64	g01927694

6. Secure the sleeve from the bottom side of the block in two places that are 180° from each other. Use two 1/4 × 20 Allen Head Screws with 25.0 mm (1.00 inch) long threads and 4C-9507 Retaining Compound. Refer to Illustration 64.

7. Drill and tap screw holes with 2/3 of the hole into the block and 1/3 into the new sleeve. The depth of the hole should be approximately 22.0 mm (0.87 inch) deep.

8. After screws are installed and tight, remove the screw head by cutting or grinding.

9. Blend the surface of the screw into the block and sleeve using a blunt ended tool with a 0.79 mm (1/32 inch) diameter and a pneumatic hammer. This will produce the appearance of a rough casting to the repaired area.

10. Finish machining inside of the sleeve to 193.65 ± 0.05 mm (7.624 ± 0.002 inch).
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    Illustration 65	g06181106
    Cross section of liner bore showing sleeve chamfer.

11. Chamfer the top of the sleeve 60°.

Repairing the Hole for the Main Bearing Bolt

The threaded holes in the main bearing bore of cylinder blocks can be damaged during an engine rebuild. Damaged threads can cause improper torque of the main bearing bolts, resulting in possible cylinder block and crankshaft failure. Bolt holes can be repaired back to the original functionality by using this repair procedure with the threaded insert.

Nomenclature

Illustration 66	g06304407
Modified 8H-8559 Extension Assembly (G) Three flats that are equally spaced

1. Remove the male square drive end (7) of the extension to the specified length that is given in Table 17.

2. Machine the extension to rest of the dimensions in Table 17.

3. Machine three equally spaced flats (6) on the end of the extension. Refer to Illustration 66.
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   Table 17

   Modified 8H-8559 Extension Assembly
   Item	Dimension
   (A)	New length 127.0 mm (5.00 inch)
   (B)	50.8 mm (2.00 inch)
   (C)	38.1 mm (1.50 inch)
   (D)	0.8 mm (0.03 inch) by 45° C/R
   (E)	Diameter 12.7 + 0.0 - 0.3 mm (0.50 + 0.00 - 0.01 inch)

Illustration 67	g01637471
The tools are for 3500 series engines. Refer to Table 18 and Table 19 for identification.

Table 18

Thread Repair Tooling (Late 3500 Series Engines with 22.23 mm (0.875 inch) bolt thread)
Item	Quantity	Part Number	Description
1	1	178-2351	Reamer
2	1	178-2353	Tap First Operation
3	1	178-2356	Tap Second Operation
4	1	178-2467	Installation Sleeve
5	1	178-2503	Threaded Insert

Table 19

Thread Repair Tooling Early 3500 Series Engines with 19.05 mm (0.750 inch) bolt thread
Item	Quantity	Part Number	Description
1	1	178-2462	Reamer
2	1	178-2463	Tap First Operation
3	1	178-2465	Tap Second Operation
4	1	178-2468	Installation Sleeve
5	1	178-2502	Threaded Insert

Repair Procedure

Note: Tapping the holes is performed by using two separate taps. Refer to Table 18 and Table 19 for the correct taps.

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Illustration 68	g01638134

1. Insert the reamer in the damaged main bearing hole.
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   Illustration 69	g06304409
   Ream damaged bolt hole.

   Note: Reaming will be easier and quieter if cutting oil or a lightweight lubricating oil is sprayed into the hole at regular intervals.

2. Secure the modified end of the 8H-8559 Extension Assembly into the chuck of the 12.7 mm (0.50 inch) variable speed drill and then tighten.

3. The internal square end of the extension should be connected to the external square drive of the reamer.

4. Use a slow rotational speed to start reaming the damaged threads. Feed the reamer with moderate pressure.

5. After reaming to a depth of 25.4 mm (1.00 inch), stop the drill and remove the reamer.

6. Clean all chips and shavings from the hole by using compressed air. Continue reaming to the bottom of the hole. Remove the reamer and thoroughly clean all chips and shavings from the hole.
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   NOTICE
   To avoid damage to the tooling, keep the reamer flutes free from metal shavings.

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   Illustration 70	g01638142
   Chamfer the bolt hole.

7. Chamfer the hole by using a tool for metal chamfering or by using the 4C-3845 Grinding Wheel.

8. Clean all chips and shavings from the hole by using compressed air.
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   Illustration 71	g01638140
   Thread the hole with the thread tap.

9. By using a handle for a tap, socket extension, tapping fluid or cutting oil, and the first tap, thread the hole until the pilot at the end of the tap bottoms.

10. Remove the tap for the first operation.

11. Clean all chips and shavings from the hole by using compressed air. Tap the hole by using the second tap.

12. Clean all remaining chips and shavings from the hole.

13. Clean the internal threads by using 138-8441 Brake Cleaner.

14. Dry the threads by using compressed air.

15. View the threaded hole by using a flashlight to ensure that there are no remaining chips.
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    Illustration 72	g01638273
    (4) Installation sleeve

16. With the hex end of the installation sleeve (4), thread the installation sleeve (4) onto a clean main bearing bolt. Thread the installation sleeve (4) to the end of the threads. Then loosen the installation sleeve about one-half to three-fourths of a turn.
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    Illustration 73	g01638275
    (5) Threaded Insert

17. Start threading the threaded insert (5) onto the same main bearing bolt. Refer to illustration 73.

18. Thread the threaded insert until the insert contacts the sleeve. Refer to illustration 74.

19. Ensure that there is a snug fit between the insert and the sleeve. There must be a snug fit between the insert and the sleeve.

20. Clean the threads on the outside diameter of the insert with 169-5464 Quick Cure Primer and allow the threads to dry.
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    Illustration 74	g01638278
    Sleeve and threaded insert

21. Coat the threads on the outside diameter of the insert with 154-9731 Thread Lock Compound.
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    Illustration 75	g06304411

22. Screw the threaded insert into the block to the bottom of the tapped hole. Use a wrench in the hex of the installation sleeve. The installation sleeve should be tightened an additional thirty degrees.

    Note: Once the insert is started in the block, continue the installation until the insert is seated at the bottom of the hole. Failure to install the insert without stopping will cause the insert to become stuck.

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    Illustration 76	g01638648

23. Loosen the installation sleeve without allowing movement of the main bearing bolt. Then, remove the bolt.

24. Use a file or a stone to remove any burrs or high spots from the mating surface of the block.

Cylinder Block Salvage Tooling

Water Ferrule Template

Illustration 77	g06181376
This template will help locate the areas needing rework on the block. (a) Drill Ø 28.58 ± 0.03 mm (1.12519 ± 0.00118 inch) 4 HOLES Marked with (an s). Press bushing flush with bottom surface. (1) Two ROLL PINS Ø 9.52 mm (0.37480 inch) (2) Drill (4) Bushings ANSI P-78-12-.8125 (3) Plate of 1018 Steel (4) Drill Bushing ANSI P-96-12-1.1875 (AA) Square plate 305 ± 3 mm (12.00 ± 0.12 inch) each side (AB) Plate Thickness 12.7 mm (0.50 inch) (AC) Roll Pin Protrusion 15 mm (0.59 inch) MAX (AD) Bushing thickness 19.1 mm (0.75 inch) (A) 200.0 ± 0.3 mm (7.87 ± 0.01 inch) (B) 105.0 ± 0.3 mm (4.13 ± 0.01 inch) (C) 52 ± 1 mm (2.05 ± 0.04 inch) (D) 54.5 ± 0.8 mm (2.15 ± 0.03 inch) (E) 11.5 ± 0.3 mm (0.45 ± 0.01 inch) (F) 16.7 ± 0.3 mm (0.61 ± 0.01 inch) (G) 90.0 ± 0.3 mm (3.54 ± 0.01 inch) (H) 100 ± 3 mm (3.94 ± 0.11 inch) (I) 145.5 ± 0.8 mm (5.73 ± 0.03 inch) (J) 188.5 ± 0.3 mm (7.42 ± 0.01 inch) (K) 216.7 ± 0.3 mm (8.53 ± 0.01 inch) (A1) 32 ± 1 mm (1.26 ± 0.04 inch) (B1) 35.8 ± 0.3 mm (1.41 ± 0.01 inch) (C1) 132.0 ± 0.3 mm (5.20 ± 0.01 inch) (D1) 204.5 ± 0.3 mm (8.05 ± 0.01 inch) (E1) 230.0 ± 0.8 mm (9.06 ± 0.03 inch) (F1) 236.7 ± 0.3 mm (9.32 ± 0.01 inch)

Liner Bore Inspection Tool

Illustration 78	g06181381
All measurements shown are in millimeters.

Counter-bore Tool Group

5P-4175 Counterboring Tool Group

This section includes a procedure to rework the base of the tool group, if necessary. Basic maintenance items are also included to keep the tool working properly. This section also contains a procedure to check the accuracy of the tool group.

Illustration 79	g01628368
Nomenclature for 5P-4175 Counterboring Tool Group

Table 20

5P-4175 Counterboring Tool Group
Item	Part Number	Description
1	5P-4175	Counterboring Tool Group
2	8H-3127(1)	Bolt
3	5P-1629(1)	Drive Group
-	5P-1628(2)	Drive As
-	5P-1627(2)	Sprocket
-	4B-9806(2)	Socket Setscrew
4	5P-1631(1)	Chain As
5	6V-2120(1)	Sprocket
6	5P-1630	Drive Adapter
-	6V-4984	Setscrew

(1)	Part of 5P-4175 Counterboring Tool Group
(2)	Part of 5P-1629 Drive Group

Modifying the Base Adapter for the Tool Group

The base of the boring tool may require modification to permit clearance for the tool holder that is used on 3500 Engines. 5P-4175 Counterboring Tool Group with a serial number of 150-Up has already been modified so this procedure is not necessary.

1. Scribe a mark on the drive assembly and the base adapter to make sure that the base is reinstalled in the original position.

2. Remove the base adapter from the drive assembly.
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   Illustration 80	g02666138
   Enlarge diameter (AB) of the base adapter to 231.6 mm (9.12 inch).

3. Turn over the base adapter and make the bore larger according to the dimensions in Illustration 80.

4. Check the bottom surface of the base adapter and remove any nicks or burrs.

5. Align the scribe marks and install the base adapter in the original position on the drive assembly.
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   Illustration 81	g01637219
   (1) Plate (2) Boring tool (3) Nut and washer

6. Assemble plate (1) on boring tool (2). Make sure that the slot on the plate is down and that the pilots on the boring tool and on the plate are clean.

7. Install the washer and nut (3). Tighten the nut to 70 ± 7 N·m (50.0 ± 5.0 lb ft).

Maintenance of the Drive Assembly

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Illustration 82	g01637245
(1) Plate (2) Boring tool (4) Knob (5) Oil level plug

1. Remove plug (5) and check the oil level in the hydraulic unit.

   Note: Boring tool group (2) must be in the horizontal position to check the oil level.

2. If necessary, fill the unit with oil and install plug (5). The correct oil for this tool is SAE 10, SAE 20, or SAE 30 oil.

3. Loosen knob (4) to release the control valve and move plate (1) in and out.

4. Remove plug (5) and check the oil level again. Fill with oil, if necessary.

   Note: If the oil level is low or the drive chain is loose, the tool will not cut smoothly.

5. Tighten knob (4).
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   Illustration 83	g01637312
   (1) Plate (6) 6V-4984 Setscrew

6. Check the adjustment of 6V-4984 Setscrew (6).

   1. To adjust the setscrew, tighten adjustment screw (6).

   2. Loosen setscrew (6) by one quarter turn.

   3. If installation of plate (1) is difficult, inspect setscrew (6) for damage. The setscrew should be replaced if the setscrew is worn.

      Note: The tool will also drag if plate (1) is worn. Inspect inside of the plate and install a new plate, if necessary.

Check the Accuracy of 5P-4175 Counterboring Tool Group

The liner seat inserts are precisely machined so the counter-bore in the top deck must be parallel to the top of the cylinder block within 0.03 mm (0.001 inch). Follow this procedure to check the accuracy of 5P-4175 Counterboring Tool Group. The tool should be checked at specific intervals to maintain accuracy. Also, check the tension of the drive chain during the inspection.

Note: The top deck of the cylinder block and the edge of the cylinder that will be counter-bored must be free of debris, carbon buildup, and burrs before the tool group is installed on the cylinder block.

The accuracy of the boring tool can be done on any cylinder block if the top deck is in good condition or the top deck is ground smooth and flat. The top deck must be smooth and flat to make sure that all depth measurements are correct. All the adjustments and settings in this procedure must be made according to the bore size of the cylinder block that is used for the accuracy check.

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Illustration 84	g01637322
(1) Plate (2) Boring tool (4) Knob

1. Position boring tool (2) on the cylinder block.

2. Release control knob (4) so plate (1) will go into the pilot bore of the cylinder liner.
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   Illustration 85	g01637327
   (7) 4C-6548 Stud (8) 6B-6682 Full Nut (9) 5P-1769 Washer

3. Use 4C-6548 Stud (7) with 5P-1769 Washer (9) and 6B-6682 Full Nut (8) to fasten the boring tool to the cylinder block. Tighten the nuts to 70 ± 7 N·m (50.0 ± 5.0 lb ft).

   Note: The tool holder must rotate freely after the nuts are tightened.

4. Move up plate (1) into the base plate and lock the plate in place with control knob (4).

5. Set the cutting tool to the correct diameter.
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   Illustration 86	g01637338
   (10) Cutter (11) Base and micrometer (12) Micrometer

   1. Install 4C-6561 Master Gauge into the base and micrometer (11). The base and micrometer are part of 9U-7986 Micrometer Depth Gauge Gp.

   2. Adjust micrometer (12) until the stem is against the master gauge.

   3. Remove the master gauge and install cutter (10).

   4. Adjust the cutter to a diameter that is 0.13 mm (0.005 inch) larger than the measured diameter of the bore.
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   Illustration 87	g01637414

6. Clean slot (13) in the plate.
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   Illustration 88	g01637377

7. Install cutter (10) and tighten screw (14).
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   Illustration 89	g01637380

8. Carefully loosen knob (4) and move down the cutter until cutter (10) is against the top deck of the cylinder block.
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   Illustration 90	g01637383

9. Put a 0.08 mm (0.003 inch) feeler gauge under adjusting nut (15). Adjust nut (15) so the nut is against the feeler gauge. Then, tighten bolt (16) to hold the adjusting nut in position.

10. Lift the plate so the cutter is approximately 1.5 mm (0.06 inch) above the top face of the cylinder block. Close the control valve.
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    Illustration 91	g01637396

11. Use a heavy-duty industrial drill and 5P-1630 Drive Adapter (17) to operate the boring tool. Remove the feeler gauge and start the cut.
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    Illustration 92	g01637537

12. Stop the cutter immediately when adjustment nut (15) contacts the positive stop.

13. Loosen knob (4) and lift the plate. Then, tighten knob (4) to hold the plate in the up position.

14. Scribe an alignment mark to locate the tool group in relation to the position on the cylinder block. Then, remove the boring tool from the cylinder block.

15. Use 8T-0455 Liner Projection Tool Group to check the depth of the cut in four locations around the counter-bore.

16. If all the measurements in Step 15 are not within 0.03 mm (0.001 inch), refer to the "Adjustment of the Counterboring Tool Group" section of this guideline. If all the measurements are within 0.03 mm (0.001 inch), the boring tool is ready to machine the cylinder blocks.

Adjustment of the Counterboring Tool Group

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Illustration 93	g01637542

1. When the deepest location of the counter-bore is known, install the counterboring tool group on the cylinder block. The tool must be installed in the original position.

2. Thoroughly clean housing group (19) and base adapter (20).

3. Loosen four bolts (18) that fasten the housing to the base adapter.
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   Illustration 94	g01637543

4. Install shims (21) between housing (19) and base adapter (20) next to the deepest point of the counter-bore. The shims must be put on each side of a bolt or the shim must have a hole for the bolt.

   Note: Shims must be installed with complete contact between the surfaces of housing (19) and base adapter (20).

   Note: A shim with thickness of 0.03 mm (0.001 inch) will normally change the depth of cut approximately 0.05 mm (0.002 inch).

5. Repeat the procedure in the "Check the Accuracy of 5P-4175 Counterboring Tool Group" section to recheck the accuracy of the boring tool.

6. Continue to add shims if the depth of cut is not within 0.03 mm (0.001 inch).

   Note: Before any machining is performed, the diameter of the bores and the flange thickness of the liner seat insert should be verified.

Tool Modifications

Modification to the 8T-2682 Plate

Illustration 95	g06181395

Illustration 96	g06181400
View AA (AC) Slot for clearance of cutter 12.7 mm (0.50 inch)

Illustration 97	g02603817
Plate that has been modified (AC) Slot for clearance of cutter 12.7 mm (0.50 inch)

The 8T-2682 Plate will need to be modified sometimes when the cutter does not fit. This modification will allow the 6V-2025 Cutter Assembly to slide deeper into the cutter slot.

The slot (AC) should be 12.7 mm (0.50 inch) wide. The slot should be 12.7 mm (0.50 inch) deep. This slot can be enlarged with a 12.7 mm (0.50 inch) end mill.

Modification to the 6V-2025 Cutter Assembly

Illustration 98	g02603841

Illustration 99	g06181403
(AD) 8.00 ± 0.50 mm (0.315 ± 0.020 inch) (AE) 11° ± 1°

The cutter will also have to be modified to chamfer the block properly. The modifications to the 6V-2025 Cutter and the 8T-2682 Plate are detailed in FT drawing FT-3166 Tool Assembly.

Note: The modified 6V-2025 Cutter can be used on previously installed non-chamfered stainless steel liner bore inserts. The cutter may wear at an accelerated rate in this case.

Always check the condition of the cutter before use to ensure proper performance.

Specifications and Salvage for Spacer Plates

Once the spacer plate is removed from the engine compare the spacer plate to the measurements in this section. Then compare the spacer plate to the types of damage that are shown in this section. If the type of wear or damage to the spacer plate is not shown to be reusable, then do not use the spacer plate again.

General Information

The 110-6994 Spacer Plate is needed with the 118-9494 Cylinder Liner that has a larger diameter of the flange.

Because the spacer plate is made out of aluminum, the spacer plate requires special handling to prevent damage.

The 110-6994 Spacer Plate replaced the 9Y-1485 Spacer Plate that replaced the 8N-6864 Spacer Plate. The 118-9494 Cylinder Liner is replacing the 110-6993 Cylinder Liner that replaced the 8N-6861 Cylinder Liner.

Nomenclature

Illustration 100	g01493683
Spacer Plate for 3500 Engines.

Table 21

Spacer Plate
Hole	Quantity	Description
1	2	Dowel Hole
2	4	Large Water Port
3	4	Small Water Port
4	8	Large Bolt Hole
5	1	Oil Supply Hole
6	2	Small Bolt Hole
7	1	Follower Pocket

General Procedure

These instructions must be followed in sequence to determine if a spacer plate is reusable.

1. Make a visual check of the general condition of the spacer plate and look for obvious damage to the spacer plate.

2. Clean the spacer plate thoroughly.

3. After cleaning the spacer plate, visually inspect the spacer plate for cracks, corrosion, erosion, and other damage.

Plate Thickness

Table 22

Plate Thickness
Part Number	Thickness	Minimum Thickness	Surface Texture
110-6994	12.313 ± 0.025 mm (0.4848 ± 0.0010 inch)	12.288 mm (0.4838 inch)	N/A
362-9677	12.333 ± 0.025 mm (0.4856 ± 0.0010 inch)	12.308 mm (0.4846 inch)	N/A
519-7297	12.363 ± 0.025 mm (0.48673 ± 0.00098 inch)	12.338 mm (0.48575 inch)	Ra 1.6 µm (62.99213 µinch) Rz 18.0 µm (708.6614 µinch)

Initial Inspection

Before cleaning the spacer plate, make a quick visual inspection for bending, scratches, deep cuts, heat, and impact damage. Do not reuse any spacer plate that has the following.

• Cracks with spalling of material

• Burned path from exhaust gas leakage with measurable width and depth in any area

Illustration 101	g01493684
Bent spacer plate or warped spacer plate

Do not use the part again.

Illustration 102	g01493685
Impact damage to the edge of the spacer plate affects the thickness of the spacer plate and the sealing capability of oil.

Do not use the part again.

Illustration 103	g01493686
Deep cut (8) between large bolt hole (4) and the hole for the clearance of the cylinder liner.

Do not use the part again.

Illustration 104	g01493687
The illustration shows a deep cut (9) around the large water port (2).

Do not use the part again.

Cleaning Aluminum Spacer Plates

The aluminum spacer plate requires more care during handling and cleaning. Extra care will prevent damage to the spacer plates, and extra care will also retain reusability. Recommended materials for cleaning are brake cleaner solvent and/or blasting with 9U-5271 Glass Beads.

Steps for cleaning aluminum spacer plates

1. Use only glass beads. Do not use aluminum oxide or an abrasive material. Do not mix any material with glass beads.

2. Do not use wire brush or wire wheel.

3. Do not sand or grind the spacer plate.

4. Do not use Scotch Brite pads to clean spacer plates.

Brake fluid can be used to clean PtFE Teflon residue from spacer plates. Glass beads should be used with certain precautions to clean aluminum plates. Glass beads tend to alter plate dimensions. Glass beads can hide cracks that are normally seen during visual inspection.

Note: Do not use glass beads that are larger than 0.2311 mm (0.0091 inch) in size to clean the spacer plate.

For the best results, use glass beads that are size 10. The size of the glass beads must be 0.0889 mm (0.0035 inch) to 0.1499 mm (0.0059 inch). The air pressure must be from 550 kPa (79.8 psi) to 620 kPa (89.9248 psi). Change the glass beads and check the nozzle regularly for best results.

Cleaning Steel Spacer Plates

The following methods are also acceptable for cleaning the steel spacer plate:

• Aluminum oxide

• Wire brush or wire wheel

• Scraping or sanding

Glass beads can be used to clean the spacer plates. Change the glass beads and check the nozzle regularly for best results. Use the following specifications for glass beads:

• Size 10 glass beads.

• 0.088 mm to 0.149 mm (0.0035 inch to 0.0059 inch)

• 550 kPa to 620 kPa (80.0 psi to 90.0 psi) air pressure

Note: Do not use glass beads that are larger than 0.23 mm (0.009 inch) to clean the spacer plate. Large glass beads may damage the spacer plate.

Visual Inspection for Unacceptable Cracks and Depressions

After cleaning, check both sides of the plate for cracks and connecting depressions on the surface due to corrosion, erosion, and handling damage in the following areas.

1. Check within 6.0 mm (0.24 inch) along the edge of the plate and the opening for the valve mechanism.

2. Check within 6.5 mm (0.26 inch) along the edge of the gasket. This area is the conjunction of the gasket and the plate.

3. Inside and 6.0 mm (0.24 inch) around oil supply hole (5).

4. Check within 6.0 mm (0.24 inch) around small water ports and large water ports (2 and 3).

Illustration 105	g01493688
Deep scratch (10) and damage (11) around oil supply hole (5).

Do not use the part again.

Do not use the spacer plate again if either type of damage is present in any of the four areas that are specified in "Visual Inspection for Unacceptable Cracks and Depressions" section.

Illustration 106	g01493689
The illustration shows the maximum allowable amount of erosion. The arrow points out erosion around the water port.

Use the part again.

Note: Do not use a spacer plate again if the spacer plate has a greater amount of erosion on any of the four areas that are mentioned in "Visual Inspection for Unacceptable Cracks and Depressions".

Areas that are outside of the areas that are mentioned in "Visual Inspection for Unacceptable Cracks and Depressions" may have depressions on the surface with a maximum depth of 1.0 mm (0.04 inch) and 6.0 mm (0.24 inch) in diameter. This applies to both sides of the plate.

Illustration 107	g01493690
Depressions (12) around small bolt hole (6) and depressions (13) along edge.

Use the part again.

Use the spacer plate again if the depressions (12) are the only damage that is present and the depressions are less than 1.0 mm (0.04 inch) in depth. Take measurements after the raised areas are removed with a file.

Do not use the part again.

Do not use the spacer plate again if the depressions (13) are present. No depressions are allowed within 6.0 mm (0.24 inch) along the edge of the spacer plate.

Illustration 108	g01493692
The arrow points to a crack without a measurable width. This kind of crack is a hairline crack.

Do not use the part again.

Precautions for Measuring the Projection of the Liner

Do not use steel washers or excessive torque to hold down the spacer plate for the measurement of projection. Instead, use brass and fibrous washers under bolt heads. Also use correct torques to prevent damage to spacer plates.

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 23

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 24

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 25

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 26

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 109	g06370992

Part Description

Table 27

Base Metal	Cast Iron
Hardness	N/A

Arc Spray Equipment and Procedure

Table 28

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 29

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 30

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 31

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 110	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 111	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 32

Main Bearing Cap Specifications
Engine Model	Dimension A	Dimension B	Dimension C
G3508, G3512, G3512E, PM3508, PM3512, PM3516, PP3516, G3516, G316B, G3516C, G3516E, G3520B, G3520C, G3520E, SPF343, SPT343 3508, 3508B, 3508C, 3512, 3512B 3516, 3516B	169.742 ± 0.020 mm (6.6827 ± 0.0007 inch)	340.030 ± 0.015 mm (13.3870 ± 0.0006 inch)	212.750 ± 0.060 mm (8.3760 ± 0.0020 inch)
3508, 3508B, 3512, 3512B, 3516, 3516B	129.891 ± 0.013 mm (5.1138 ± 0.0005 inch)	340.000 ± 0.015 mm (13.3860 ± 0.0005 inch)	212.750 ± 0.060 mm (8.3760 ± 0.0020 inch)

Part Description

Table 33

Base Metal	Hardness
Cast Iron	28 - 34 Rc

Arc Spray Equipment and Procedure

Table 34

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 35

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 36

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 37

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 112.

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 113.

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

Illustration 112	g06278538
Example of protection for a component that is stored for a shorter term

Illustration 113	g06278539
Example of protection for a component that is stored for a longer period