Using the 6V-7840 Deck Checking Tool Assembly {0701, 1201, 7225} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

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

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Canceled Part Numbers and Replaced Part Numbers

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Important Safety Information

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

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.

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This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

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

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

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

Summary

When an engine is being rebuilt, it can be important to know if the top deck of the cylinder block has been machined. The 6V-7840 Deck Checking Tool As can accurately measure the distance from the centerline of the crankshaft to the top deck of the block. The tool can measure all deck heights within a range of 200.0 mm to 625.0 mm (7.87 inch to 24.60 inch). Measuring the top deck will also allow you to determine how much material can still be removed and keep the engine within the minimum specifications.

Service Letters and Technical Information Bulletins

Measurement Requirements

6V-7840 6V-78406V-7840 6V-7840Components of 6V-7840 Deck Checking Tool

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(1) Lower Knob (2) Lower Clamp (3) Standard Stop (4) Parallel Plate (5) Micrometer (6) Adjusting Collar (7) Locknut (8) Shaft Knob (9) Lower bar (10) 4B-9820 Wrench (1/8 inch), 7B-7640 Wrench (5/32 inch), 6B-7225 Wrench (3/16 inch) (11) Standard Wrench (12) Standard (13) Measuring Standards (14) Standard Extensions

Checking the Setting and Accuracy of the Tool

Before initial use of the tool the position of standard stop (1) and the accuracy of micrometer (2) can be checked by using the following information.

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1. To check the position of standard stop (1), put lower bar (3) in lower clamp (4) and tighten knob (5). Use standard (6) [marked "STANDARD"] to check the distance between lower bar (3) and standard stop (1). If necessary, adjust the position of standard stop (1) by loosening screws (7), moving the stop as needed, then tightening screws (7).
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2. To check the accuracy of micrometer (2), put a flat ground block (8) against the bottom of parallel plate (9). Adjust the micrometer until spindle (A) is against block (8). The micrometer should read "0". If necessary, adjust the position of the micrometer by loosening screw (10), moving the micrometer as needed, then tightening screw (10).

Checking Distance From Crankshaft Centerline to Top Deck of Cylinder Block

1. Look at the table 1 to find the correct tool reading for the engine being measured. Look at table 2 to find the measuring standards and extensions needed. For example, a new 3406 cylinder block will have a tool reading of 360.50 ± 0.06 mm (14.193 ± 0.002 inch). This reading is in the 350 to 375 range, and will therefore take a 25 measuring standard plus one 150 extension.
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2. Install correct measuring standard (1) on standard stop (2). Use wrench (3) to tighten standard (1). Do not tighten standard (1) too much. Adjust micrometer (4) until the micrometer it reads "0". Loosen locknut (5), and put the tool assembly down into position in one of the end cylinders.

   Note: Always check the crankshaft centerline to top deck distance (deck height) at both ends of the cylinder block.

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3. Put lower bar (6) in position in lower clamp (7). Make sure bar (6) is centered in clamp (7), then tighten lower knob (8). Hold knob (9) and lift on the tool assembly until lower bar (6) is against the top of the main bearing bores. Loosen setscrew (10) and slide parallel plate (11) down until the plate is firmly against the top deck of the cylinder block. Tighten setscrew (10).
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4. Hold knob (9) and gently move the tool back and forth while turning adjusting collar (12) clockwise until all slack is removed: tighten collar (12) finger tight only. Adjust micrometer (4) until the micrometer touches the measuring standard. Read the micrometer. Make a record of this reading.

5. To find the tool reading, add the micrometer reading to the first number in the column "To Measure Distances" in Table 3. To calculate the actual deck height, add 1/2 the main bearing bore (shown in column 3 of Table 2) to the tool reading. IMPORTANT: If the main bearing bore has been machined for oversize bearings, do not use the value shown in column 3. Instead measure the bore and add 1/2 of this value to the actual tool reading (not the value shown in column 2). Both main bearing bores in contact with the lower bar must be the same size.

   EXAMPLE 1: If a 3406 cylinder block (with standard main bearing bores) has a micrometer reading of 10.52, add this reading to the first number (350) to get a tool reading of 360.52. The actual distance from the crankshaft centerline to the top of the block can be calculated by adding 1/2 x 129.891 + 360.52 to get a deck height 425.47.

   EXAMPLE 2: If a 3406 cylinder block has 0.635 mm (0.0250 inch) over size main bearing bores and a micrometer reading of 10.16, add this reading to the first number (350) to get a tool reading of 360.16. To calculate the actual distance from crankshaft centerline to top of block, add 1/2 x 130.526 (bore measurement) + 360.16 to get a deck height of 425.42.

6. After the deck height has been calculated in the previous step compare this value to , "Crankshaft Centerline to Top of Cylinder Block" in Table 2. This comparison will show if the block deck has been machined. See the specifications In the Guideline for reusable Parts for Cylinder Blocks for information on the machining of cylinder blocks.

Note: If the main bearing bore has been machined for oversize bearings, subtract 1/2 of the bore from the "Crankshaft Centerline to Top of Cylinder Block" dimension to get the tool reading. Both main bearing bores in contact with the lower bar must be the same size.