Cylinder Block Salvage Procedure Using Belzona® 1311 (Ceramic R Metal) {0700, 0701, 1000, 1201} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

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

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

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

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

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

Canceled Part Numbers and Replaced Part Numbers

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

Important Safety Information

Illustration 1	g02139237

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

Show/hide table

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

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

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

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

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

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

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

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

Summary

This guideline provides the procedure and the necessary materials for the salvage of cylinder blocks with the use of Belzona® 1311 (Ceramic R Metal).

Service Letters and Technical Information Bulletins

Tooling and Equipment

Procedure to Repair Pitting in the Liner Bore Holes Using Belzona® 1311 (Ceramic R Metal)

Examples of Erosion

Illustration 3	g06303985
Pitting has occurred in the cylinder bore (head bolt boss).

Illustration 4	g06303987
Pitting has occurred in the sidewall of the cylinder block.

Illustration 3 and Illustration 4 show the types of erosion that can be repaired with the use of Belzona® 1311 (Ceramic R Metal).

Surface Preparation

After all machining or salvage work has been completed, then thoroughly clean the cylinder bore.

Note: The cylinder block must NOT be put in a caustic solution after the Belzona® 1311 (Ceramic R Metal) repair has been applied.

Illustration 5	g06303988
Deep pitting has occurred within the cylinder liner bore.

Illustration 6	g06303990
Pitting is removed with a pneumatic needle scaler.

1. If the eroded area contains deep pitting, all corrosion must be removed from the pitted area. Refer to Illustration 5. This removal process can be manually performed by using an ice pick or by using a pneumatic needle scaler. Refer to Illustration 6

   Note: Do NOT apply excessive force against the thin wall section of a cylinder block. Excessive force may cause breaks and cracks in the thin wall.

   Show/hide table

   Illustration 7	g06303992

2. After the corrosion has been removed, then grind the entire repair area. Grind an extra 25.4 mm (1.0 inch) around the outer edge of the damage. The grinding will provide a rough finish for good adhesion for the repair material. This grinding can usually be done with an electric grinder and a medium coarse carbide bit or with a rotary file.

3. Apply light pressure only. Allow the tool to bounce slightly to produce the maximum roughness. If the section to be repaired has limited clearance with a cylinder liner, then remove more metal if necessary. A slight build-up with the Belzona® 1311 (Ceramic R Metal) repair material is desired.

   Note: Do NOT grind through the cylinder block. Do NOT remove more than 3.1 mm (0.125 inch) of the base material.

4. After the required finish of the surface has been obtained, then clean the area that will be repaired.

   Note: All dirt and oil residue must be removed. Use the cleaner/degreaser to thoroughly clean the area that will be repaired.

5. Use a clean shop towel to check the cleanliness of the area that will be repaired. Repeat the cleaning procedure until the area is clean. After the final cleanliness check, apply the cleaner/degreaser again. Allow the cleaner/degreaser to air dry without contacting the surface.

   Note: The finish and cleanliness of the surface are essential for a successful repair.

Application of Repair Material

Mixing the Repair Material

1. To make the repair material, use the supplied tools or a clean putty knife. Mix one part solidification mixture to three parts (by volume) of the base material.

   Note: The recommended mixture of one part solidification to three parts base material must not be exceeded. Incorrect mixture ratio will result in a reduction of the final strength of the repair.

2. Mix the repair materials only in small amounts. This method allows time for the application of the repair material before hardening and becomes difficult to apply.

   Note: The time required for the repair material to solidify will vary according to the ambient temperature. The repair material will solidify faster at warmer temperatures and slower at cooler temperatures. Refer to the "Temperature and Time" chart included with the Belzona® 1311 (Ceramic R Metal) repair material.

3. The preferred method of blending the repair material is performed by spreading the material then folding the material back onto itself. Repeat the process of spreading and folding until mixing is complete. The repair material is mixed when a consistent color is achieved.

   Note: Do not place the material in a pile. Piling the repair material will cause it to cure faster and shorten the working time. Keep the material spread out to slow the cure time and lengthen the working time.

   Note: No more than two cylinder liner bores should be repaired at the same time. Adherence to this rule should be maintained until additional experience with the characteristics of the repair material is achieved.

   Show/hide table

   Illustration 8	g06303994
   Repair material is applied into the holes and into the pitted areas.

4. Apply small amounts of the repair material into the prepared areas. Firmly apply the repair material to remove any air pockets that may have formed.
   Show/hide table

   Illustration 9	g06303995

5. Build up the repair material in thin layers to original dimensions. A smooth finish is not necessary now, it will be machined in a later step. Place special attention to the clearances of the cylinder liner while building up the repair material. There is a tendency to apply too much of the repair material resulting in an increased final machining time. Ensure that the edges of the repair material are tapered. Tapering the repair material helps to blend it into the surrounding metal. Keep the repair material only on the area that has been prepared and cleaned. Any material that mistakenly extends beyond this area must be removed.

Surface Finishing the Repaired Area

1. After approximately 30 minutes from the original mixing time, the applied repair material can be smoothed. Put on rubber gloves and check the surface of the repair material. The check will determine the condition of the surface. The surface may look like a dried film and may also be slightly sticky. If the repair material sticks to the finger of the glove it is too wet.

2. Dip the fingers of your glove in water. Rub the surface of the repair with wet fingers to get a smooth finish. Use only enough water to wet the glove. Too much water can have an adverse effect on the strength of the Belzona® 1311 (Ceramic R Metal) repair.

3. Press firmly to expel any air that may have been trapped in the repair material during the smoothing process. Correctly done, the smoothing process will reduce the required time to grind once the Belzona® 1311 (Ceramic R Metal) repair material has cured.
   Show/hide table

   Illustration 10	g06303997
   The finish grind of the repaired area has been performed on the repair material.

   Note: When the Belzona® 1311 (Ceramic R Metal) is correctly mixed and used at a temperature of 21° C (70° F), the repair material will develop full mechanical strength in 24 hours.

4. At room temperature the repair material will be ready for finish grind two hours after application. In the close clearance areas, grind away enough material to return the piece back to the original dimensions. The other areas should be left with a slight buildup of the repair material for resistance of future erosion.

5. The block is now ready for cleaning and reassembly.

Procedure to Repair Pitting on the Cylinder Block Top Deck Using Belzona® 1311 (Ceramic R Metal)

A cylinder block top deck can be repaired with Belzona® 1311 (Ceramic R Metal).

Pitting of the cylinder block that is 0.13 mm (0.005 inch) deep or deeper can be repaired using this procedure. This procedure can be utilized if the pitting extends completely around (360 degrees) the water port. If pitting is less than 0.13 mm (0.005 inch) deep, resurfacing the top deck is another method of removing the damage.

Illustration 11	g01513255
(1) pitting around water passages

Rework Procedure

The basic procedure involves removing the circular pitting using a hole saw. The groove that is made from the hole saw will be filled by using Belzona® 1311 (Ceramic R Metal).

1. Modify the hole saw. Before using the hole saw, the cutting teeth must be modified. New teeth will cut a groove with a small radius between the sides and bottom of the groove. The small radius will increase the stress concentration in the groove that could lead to cracking.

   1. Mount the hole saw in a drill.

   2. Operate the drill in reverse, and use a file to round off the outside edge of the teeth.

      Note: Each hole saw will only need to have the teeth filed one time. The inside edge of the hole saw does NOT require modifying.

   Show/hide table

   Illustration 12	g02915449

2. Thoroughly clean the surface of the block. Use a good quality solvent and remove all dirt, oil, and grease from the top deck.
   Show/hide table

   Illustration 13	g02915561

3. Use two locating dowels (1) and install a spacer plate over the cylinder that is to be reworked. Use two bolts (2) to tighten the spacer plate to the block. Tighten the bolts only enough to keep the spacer plate from moving.

   Note: The spacer plate is used only as a guide for the hole saw. The spacer plate will be damaged during this operation and should NOT be installed again on an engine. Continue to use the same spacer plate for the remaining rework procedure on the engine.

4. Select the correct hole saw and the drill speed from the following chart.
   Show/hide table

   Table 3

   Hole Saw Selection and Drill Speed
   Water Port Size	Hole Saw Diameter	Drill Speed
   Small	19 mm (0.75 inch)	100 RPM
   Large	28.4 mm (1.12 inch)	75 RPM

   Show/hide table

   Illustration 14	g02915901

5. Using the spacer plate as a guide, cut a circular groove in the block 0.8 mm (0.03 inch) to 1.5 mm (0.06 inch) deep. Do not cut too deep. Normally, 15 to 30 seconds of cutting time will produce the correct depth.

6. Repeat this procedure for all the holes that require repair.
   Show/hide table

   Illustration 15	g02915957
   A cylinder with all the pitting removed from the large diameter water ports.

   Show/hide table

   Illustration 16	g02915959
   A close up view of the water port. Note the roughness of the groove bottom.

7. Remove the spacer plate. Remove all chips and machining debris.
   Show/hide table

   Illustration 17	g02916478
   Using a torch to heat the surface of the block

8. Carefully heat the area around the machined groove to remove any grease or oil from the groove. A small amount of heat is required to remove moisture from the machined groove.

   Note: The surface temperature of the block must NOT exceed 315° C (600° F) or damage to the block surface may result. Use an infrared thermometer to measure the block surface temperature.

9. A degreasing solvent, such as 8T-9011 Component Cleaner or 4C-4079 Brake and Electrical Cleaner should be used to clean the surface of the block again after the temperature of the block has lowered.
   Show/hide table

   Illustration 18	g02916517
   Mixing the Belzona

10. Follow the Belzona instructions for proper use.

    Note: Use only Belzona that is less than 3 years old. Use only Belzona® 1311 (Ceramic R Metal) that has been stored at temperatures below 29° C (85° F). Complete mixing is important. Following the initial mixing the Belzona® 1311 (Ceramic R Metal) should be removed from the first mixing board and placed on a second board. The mixing tool should be wiped clean and the material further mixed to eliminate any small pockets of unmixed resin or solidifier.

    Show/hide table

    Illustration 19	g01649100

    Show/hide table

    Illustration 20	g02916556
    Cover all the grooves with Belzona at the same time.

11. Apply the Belzona in small amounts to the area to be repaired. Use a criss-cross motion to remove any trapped air bubbles. Use a flat stick or a putty knife to work the Belzona into the machined groove of the block. Leave the Belzona® 1311 (Ceramic R Metal) material slightly higher than the surface of the block. Any material that flows into the actual water passage can be removed later.

    Note: The working time of the Belzona® 1311 (Ceramic R Metal) is directly affected by the temperature of the air. Use the following charts to help identify the working times and the hardening times of the Belzona® 1311 (Ceramic R Metal).

    Show/hide table

    Table 4

    Working time of Belzona® 1311 (Ceramic R Metal) based on temperature
    Ambient Temperature	Time
    5° C (41° F)	35 minutes
    15° C (59° F)	25 minutes
    25° C (77° F)	15 minutes

    Show/hide table

    Table 5

    Approximate Hardening Times for Belzona® 1311 (Ceramic R Metal)
    Ambient Temp	A	B	C	D
    5° C (41° F)	4 hours	6 hours	four days	five days
    10° C (50° F)	3 hours	4 hours	two days	four days
    15° C (59° F)	2 1/4 hours	3 hours	1 1/2 days	three days
    20° C (68° F)	1 3/4 hours	2 hours	one day	two days
    25° C (77° F)	1 hour	1 1/2 hours	20 hours	1 1/2 days
    30° C (86° F)	3/4 hours	1 hour	16 hours	one day

    • A - Remove excess material from around the machined groove

    • B - File down the Belzona® 1311 (Ceramic R Metal) to match the block surface

    • C - Full mechanical or thermal loading

    • D - Immersion in chemicals
    Show/hide table

    Illustration 21	g02917336

    Show/hide table

    Illustration 22	g02917602
    When the Belzona® 1311 (Ceramic R Metal) begins to set up around the holes, scrape off the excess material.

12. Remove any excess material from the water passages before the material is dry. Use Table 5 to determine when to scrape away the excess Belzona® 1311 (Ceramic R Metal) from the area surrounding the groove. Do NOT scrape over the groove or close enough to the groove to disturb the material in the groove. By now, the material should be stiff like putty. Scraping too close to the machined groove will likely break the mechanical bond that is forming in the groove region.
    Show/hide table

    Illustration 23	g02917799

    Show/hide table

    Illustration 24	g02917816
    Using a large flat file to remove the excess Belzona® 1311 (Ceramic R Metal)

13. As the Belzona® 1311 (Ceramic R Metal) continues to harden, use a file to remove the remaining Belzona. Use a large flat file to remove the Belzona® 1311 (Ceramic R Metal) material until the Belzona® 1311 (Ceramic R Metal) material is level with the block.

    If necessary, the block can be machined after repairing with Belzona® 1311 (Ceramic R Metal). However, the final thickness of the Belzona® 1311 (Ceramic R Metal) must not be less than 0.76 mm (0.030 in) after machining. The curing time of the Belzona® 1311 (Ceramic R Metal) can be decreased by applying heat for 2 to 4 hours after applying the Belzona® 1311 (Ceramic R Metal). Using heat lamps or forced air heaters is acceptable.

    Show/hide table

    Illustration 25	g02918476

14. The repair is now complete. Allow the Belzona® 1311 (Ceramic R Metal) to harden fully before assembly.

Ordering the Repair Material

North America

Canada

Europe

Asia