2011/03/16 Caterpillar

Excavator:

5130 (S/N: 7TJ1-UP; 5ZL1-UP)

5130B (S/N: 4CS1-UP)

5230 (S/N: 7LL1-UP)

5230B (S/N: 4HZ1-UP)

Off-Highway Truck/Tractor:

776C (S/N: 2TK1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; AGY1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

785D (S/N: MSY1-UP)

789 (S/N: 9ZC1-UP)

789C (S/N: 2BW1-UP)

789D (S/N: SPD1-UP; SHH1-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

Track-Type Tractor:

D11N (S/N: 4HK1-UP; 74Z1-UP)

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

Wheel Dozer:

854G (S/N: AMP1-UP; 1JW1-UP)

Wheel Loader:

992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)

994 (S/N: 9YF1-UP)

994D (S/N: 3TZ1-UP)

994F (S/N: 4421-UP)

Service Magazine SEPD1466, 16 July 2012, "A New Cylinder Head Gasket and Spacer Plate Are Used for 3500 Machine Engines". The article has been revised for clarification of the spacer plate and gasket. No other information has changed.

Description of Change: A new multi-layered steel cylinder head gasket and a new spacer plate are used.

The new cylinder head gasket can be used with the new spacer plate and with the old spacer plate without the cut away.

Illustration 1	g03748159

Note: The new cylinder head gasket cannot be used with older versions of the old spacer plate that have a cut away area near the spacer plate oil passage. The old cylinder head gasket can be used with the new spacer plate and with the old spacer plate.

The new spacer plate requires a new specification for cylinder liner projection.

The new cylinder head gasket requires a new torque procedure for the cylinder head bolts.

Adaptable To: The part numbers of the new cylinder head gasket and spacer plate are listed in Illustration 2 and Table 1. The old part numbers are not canceled.

Illustration 2	g02453204
(1) 362-8264 Cylinder Head Gasket (2) 362-9677 Spacer Plate (3) 144-5692 Plate Gasket (4) 420-0652 Water Seal Assembly (5) 420-0653 Water Seal Assembly

Table 1

New Part	Description	Old Part	Qty Per Cylinder
362-8264	Cylinder Head Gasket	110-6991	1
362-9677	Spacer Plate	110-6994	1
144-5692	Plate Gasket	-	1
420-0652	Water Seal Assembly	-	4
420-0653	Water Seal Assembly	-	4

This change is effective for the engine serial numbers listed in Table 2.

Effective remanufactured engine serial numbers are listed in Table 3.

Table 2

Machine	Machine Serial Number	Effective Engine Serial Number
5130B Excavator	S/N:4CS	S/N:2GR8278-UP
5230 Excavator	S/N:7LL	S/N:2PK1673-UP
5230B Excavator	S/N:4HZ	S/N:7TR2930-UP
785C Off-Highway Truck/Tractor	S/N:1HW	S/N:8BR2516-UP
789C Off-Highway Truck/Tractor	S/N:2BW	S/N:7TR2930-UP
777D Off-Highway Truck/Tractor	S/N:3PR	S/N:2GR8278-UP
777C Off-Highway Truck/Tractor	S/N:4XJ	S/N:7YG2253-UP
785B Off-Highway Truck/Tractor	S/N:6HK	S/N:4WJ1381-UP
777D Off-Highway Truck/Tractor	S/N:2YW	S/N:8BR2516-UP
	S/N:FKR	S/N:C8T00967-UP
797 Off-Highway Truck/Tractor (Front Engine)	S/N:5YW	S/N:1AW1023-UP
797 Off-Highway Truck/Tractor (Rear Engine)	S/N:5YW	S/N:2CS1453-UP
785C Off-Highway Truck/Tractor	S/N:5AZ	S/N:7TR2930-UP
793C Off-Highway Truck/Tractor	S/N:4AR	S/N:7TR2800-UP
793C Off-Highway Truck/Tractor	S/N:ATY	S/N:8WM2506-UP
793B Off-Highway Truck/Tractor	S/N:1HL	S/N:2PK1668-UP
777D Off-Highway Truck/Tractor	S/N:AGC	S/N:2GR8278-UP
793C Off-Highway Truck/Tractor	S/N:4GZ	S/N:7TR2800-UP
789 Off-Highway Truck/Tractor	S/N:7EK	S/N:2PK1673-UP
785C Off-Highway Truck/Tractor	S/N:2PZ	S/N:8BR2516-UP
793C Off-Highway Truck/Tractor	S/N:ATY	S/N:7TR2800-UP
777D Off-Highway Truck/Tractor	S/N:AFS	S/N:2GR8278-UP
793C Off-Highway Truck/Tractor	S/N:CBR	S/N:8WM2506-UP
777D Off-Highway Truck/Tractor	S/N:AGY	S/N:8BR2516-UP
785 Off-Highway Truck/Tractor	S/N:8GB	S/N:96Z945-UP
797B Off-Highway Truck/Tractor (Tandem Engine)	S/N:JSM	S/N:3TN954-UP
797B Off-Highway Truck/Tractor (Front Engine)	S/N:JSM	S/N:1AW1022-UP
797B Off-Highway Truck/Tractor (Rear Engine)	S/N:JSM	S/N:2CS1452-UP
793D Off-Highway Truck/Tractor	S/N:FDB	S/N:7TR2797-UP
793D Off-Highway Truck/Tractor	S/N:FDB	S/N:8WM2504-UP
789C Off-Highway Truck/Tractor	S/N:2BW	S/N:8WM2673
785D Off-Highway Truck/Tractor	S/N:MSY	S/N:B7F329-UP
777B Off-Highway Truck/Tractor	S/N:4YC	S/N:2GR8278-UP
777C Off-Highway Truck/Tractor	S/N:4XJ	S/N:2GR8278-UP
777B Off-Highway Truck/Tractor	S/N:4YC	S/N:99W3591-UP
789 Off-Highway Truck/Tractor	S/N:9ZC	S/N:54Z1212
785C Off-Highway Truck/Tractor	S/N:APX	S/N:8BR2516-UP
793D Off-Highway Truck/Tractor	S/N:3SJ	S/N:54Z1212-UP
D11N Track-Type Tractor	S/N:74Z	S/N:99W3591-UP
D11N Track-Type Tractor	S/N:74Z	S/N:2GR8278-UP
D11R Track-Type Tractor	S/N:7PZ	S/N:2GR8278-UP
D11R Track-Type Tractor	S/N:9TR	S/N:2GR8278-UP
D11R Track-Type Tractor	S/N:8ZR	S/N:7YG2253-UP
992G Wheel Loader	S/N:7HR	S/N:2GR8278-UP
992G Wheel Loader	S/N:AMP	S/N:2GR8278-UP
992G Wheel Loader	S/N:AZX	S/N:2GR8278-UP
994 Wheel Loader	S/N:9YF	S/N:54Z1212-UP
994D Wheel Loader	S/N:3TZ	S/N:7TR2930-UP
994F Wheel Loader	S/N:442	S/N:8WM2673-UP

Table 3

Remanufactured Engine Effectivity for the New Cylinder Head Gasket and Spacer Plate
Engine Arrangement	Serial Number
10R-0946 Engine Ar	S/N:KNS00570
0R-7568 Engine Ar	S/N:CPW01217
	S/N:SPW00102
10R-2852 Engine Ar	S/N:MSK00253
10R-1433 Engine Ar	S/N:NPM00246
0R-8551 Engine Ar	S/N:5XS01058
0R-9840 Engine Ar	S/N:BTB00351
0R-9844 Complete Engine Ar	S/N:SDW00391
10R-6700 Complete Engine Ar	S/N:SDW00392
0R-3981 Engine Ar	S/N:5TL01071
0R-9551 Engine Ar	S/N:7DS01089
0R-9842 Engine Ar	S/N:KAM00385
0R-3951 Engine Ar	S/N:4ZL01487
0R-3982 Engine Ar	S/N:6FL00990
0R-9558 Engine Ar	S/N:7DS01090
0R-9583 Engine Ar	S/N:7CL02070
0R-9659 Engine Ar	S/N:7CL02071
0R-3953 Engine Ar	S/N:6CL00649
0R-8553 Engine Ar	S/N:5XS01064
0R-8558 Engine Ar	S/N:7DS01092
0R-9845 Complete Engine Ar	S/N:7DS01091
10R-6702 Engine Ar	S/N:7DS01093
0R-3985 Engine Ar	S/N:5TL01078
0R-3950 Engine Ar	S/N:4ZL01490
0R-3983 Engine Ar	S/N:7CL02079
0R-8554 Engine Ar	S/N:6SS00221
0R-9843 Engine Ar	S/N:BWA00195
0R-8555 Engine Ar	S/N:7DS01102
0R-8550 Engine Ar	S/N:5XS01076
0R-3980 Engine Ar	S/N:5TL1083
0R-8556 Engine Ar	S/N:7DS1111
10R-9195 Engine Ar	S/N:KAM00389
0R-9557 Engine Ar	S/N:7DS01114
10R-5596 Engine Ar	S/N:BTR00621
0R-3959 Engine Ar	S/N:7CL02090
0R-3986 Engine Ar	S/N:7CL02091
0R-3952 Engine Ar	S/N:5EL00420
0R-3955 Engine Ar	S/N:6CL00653
0R-8552 Engine Ar	S/N:5XS01083
0R-8557 Engine Ar	S/N:7DS01140
10R-2851 Engine Ar	S/N:7DS01143
10R-2854 Engine Ar	S/N:MSX00264
10R-7930 Engine Ar	S/N:SPM00421
10R-7931 Engine Ar	S/N:SKN00360

Measuring Wear of the Cylinder Block at the Cylinder Liner Contact Surface

Illustration 3	g02657157
Points at which to measure the depth of the wear around the circumference of the cylinder bore

Illustration 4	g02658239
Using tool (A) to measure the depth of the wear in the cylinder block under the cylinder liner flange

Use tool (A) to measure the depth of the wear in the cylinder block in the area under the cylinder liner flange. Take measurements at the eight points that are identified in Illustration 3. Illustration 4 demonstrates proper placement of the dial indicator between the tapped hole and the cylinder bore.

If the depth of the wear under the cylinder liner flange is greater than 0.013 mm (0.0005 inch), the block must be salvaged according to Reuse and Salvage Guidelines, SEBF8255, "Procedure to Salvage Top Decks of Cylinder Blocks of 3500 Engines".

Calculating Cylinder Liner Projection

The liner projection measurements outlined in tables 5 and 6 are specific to the gasket part number, regardless of the spacer plate.

The following method for calculating the liner projection is the preferred method under these circumstances:

• Single cylinder head joint repair

• Engine rebuild

This procedure also enables use of the 110-6994 Spacer Plate with the new 362-8264 Cylinder Head Gasket .

Note: When installation of spare used spacer plates and cylinder liners is desired, having the stocked parts measured and matched will reduce repair time.

Note: The method of measuring liner projection that uses the 8T-0455 Liner Projection Tool Group can still be used.

The contact surface of the cylinder block for the liner flange and spacer plate must be thoroughly clean before installation of replacement parts.

If a new spacer plate and cylinder liner will be installed in the same cylinder, there is no need to calculate the cylinder liner projection. The production process control for the parts is adequate.

If a used spacer plate or cylinder liner will be installed, perform the following measurement and calculation procedure.

Table 4

Required Tools
A	8T-0455 Liner Projection Tool Group
B	Digital micrometer with a resolution of 0.001 mm

The cylinder liner projection is now a calculation based on measurement of parts that uses the following dimensions:

• The average thickness of the flange for the 211-7826 Cylinder Block Liner, measured in four places

• The average thickness of the 362-9677 Spacer Plate, measured in four places

• The nominal manufactured thickness of a new 144-5692 Plate Gasket

A new 144-5692 Plate Gasket must be installed with the spacer plate and cylinder liner.

Use the following procedure to calculate the cylinder liner projection.

Show/hide table



Illustration 5	g02657236
(X) Average thickness of the spacer plate (Y) Nominal thickness of the spacer plate gasket (Z) Average thickness of the cylinder liner flange

1. Use tool (B) to measure the thickness of the cylinder liner flange at four equally spaced locations around the circumference of the flange. Determine the average of the measurements.

   The result is dimension (Z). Mark the result on the cylinder liner with a permanent marker. Do not scribe the material.

Show/hide table



Illustration 6	g02657156

2. Use tool (B) to measure the thickness of the spacer plate at the four locations identified by "X" in Illustration 6. Determine the average of the measurements.

   The result is measurement (X). Mark the result on the spacer plate with a permanent marker. Do not scribe the material.

3. Compare the average measurements to the dimensions listed in Table 5 and 6.

   If the average measured dimensions are within the acceptable range, the parts can be installed.

   If the average measured dimensions are not within the acceptable range, the parts cannot be installed. New parts must be obtained.

   Note: There is no need to measure the thickness of the 144-5692 Plate Gasket because a new gasket is always installed. The nominal manufacturing dimension is used in the calculation.

   Show/hide table

   Table 5

   Dimensions for Acceptable Cylinder Liner Projection with the 362-8264 Cylinder Head Gasket
   Part	Dimension	Value
   211-7826 Cylinder Block Liner flange	12.65 ± 0.02 mm (0.498 ± 0.0001 inch)	Z
   362-9677 Spacer Plate	12.33 ± 0.03 mm (0.4854 ± 0.0012 inch)	X
   110-6994 Spacer Plate	12.31 ± 0.03 mm (0.4846 ± 0.0012 inch)	X
   144-5692 Plate Gasket	0.21 ± 0.03 mm (0.008 ± 0.001 inch)	Y
   Allowable projection	0.08 mm (0.003 inch) to 0.15 mm (0.006 inch)

   Show/hide table

   Table 6

   Dimensions for Acceptable Cylinder Liner Projection with the 110-6991 Cylinder Head Gasket
   Part	Dimension	Value
   211-7826 Cylinder Block Liner flange	12.65 ± 0.02 mm (0.498 ± 0.0001 inch)	Z
   110-6994 Spacer Plate	12.31 ± 0.03 mm (0.4846 ± 0.0012 inch)	X
   362-9677 Spacer Plate	12.33 ± 0.03 mm (0.4854 ± 0.0012 inch)	X
   144-5692 Plate Gasket	0.21 ± 0.03 mm (0.008 ± 0.001 inch)	Y
   Allowable projection	0.06 mm (0.002 inch) to 0.20 mm (0.008 inch)

   Note: The cylinder liner projection is determined by subtracting the thickness of the spacer plate (X) and the gasket (Y) from the thickness of the flange (Z).

Spacer plates and cylinder liners with minimum or maximum measurements may not meet the allowable projection. In these cases, use a different spacer plate or cylinder liner.

Refer to the engine Disassembly and Assembly manual to make sure that the cylinder liner is properly installed.

Cylinder Head Bolt Tightening Procedure

Use the following tightening procedure for cylinder head bolts when the 362-8264 Cylinder Head Gasket is installed.

Show/hide table



Illustration 7	g02238396

1. Coat the threads of the bolts with clean engine oil.

   1. Tighten Bolt (1) through Bolt (8) to a torque of 30 ± 5 N·m (22 ± 4 lb ft).

   2. Tighten Bolt (1) through Bolt (8) to a torque of 100 ± 15 N·m (75 ± 11 lb ft).

   3. Tighten Bolt (1) through Bolt (8) to a torque of 450 ± 15 N·m (330 ± 11 lb ft).

   4. Loosen Bolt (1) through Bolt (8) an angle of 90 ± 5 degrees.

   5. Tighten Bolt (1) through Bolt (8) to a torque of 490 ± 15 N·m (360 ± 11 lb ft).

   6. Tighten Bolts (9) and (10) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).