Cylinder Block Cleaning and Audit Procedure {0644, 0680, 0701} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

© 2018 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.

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Canceled Part Numbers and Replaced Part Numbers

This document may 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

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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.

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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.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2for an example of a “WARNING” Safety Alert Symbol.

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.

Service Letters and Technical Information Bulletins

Summary

This guideline provides the procedures to clean and check for cleanliness of all engine blocks.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part can be expected to reach the next Planned Component Repair (PCR). Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable.

If there are large amounts of debris/mud found in the coolant system, specifically behind the upper and lower rear coolant passages. Investigate the coolant maintenance/cleanliness of the engine.

Reference Media

Required Tooling & Parts for Cleaning

If Using Cat Nylon Bristle Brushes

Illustration 3	g06180533
(A) Nylon Brush (B) 4C-4426 Extension

If Cat nylon bristle brushes are used to clean a bores, a 305 mm (12.0 inch) 4C-4426 Extension (B) is required to attach the brushes to the extension. Select the appropriately sized brush, based on the bore size.

1. To use the 4C-4426 Extension (B), cut the twisted wire handle off nylon bristle brush (A) to the length needed to perform the task.

2. Slide the twisted wire handle into extension .

3. Use the two setscrews to hold the brush in place.

Engine Block Cleaning Overview

Use the following flows chart to help process the cleaning of the engine block to assembly.

Illustration 4	g06217938
Engine block cleaning flow chart

Manual Rough Cleaning

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

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

1. Create an adequate area to manually clean the engine block. Install curtains to protect others in the area.

2. Wear personal protective equipment (PPE) throughout the whole process and ensure that all tooling has proper guards and shields in place.

3. Use 420-9053 Engine Block Lifting Tool move engine block to the area where the cleaning with begin. Position engine block on clean 524-0008 Block Cribbing or wooden pallet with cylinder bores position upward.

4. Use airgun with shield and blow rust preventive from all holes on the top deck, right and left banks, and ends of block (some liquid can be used in the holes from the Non-Destructive Testing (NDT) process.)
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   Illustration 5	g06210346
   (B) 4C-4426 Extension (C) Straight Wire End Brush

   Note: Manual cleaning should not be excessively aggressive which can cause damage to the components.

5. Detail all threaded holes on the cambox top deck, left and right banks. Use the correct diameter brush for cam box, stud pin bores, and cylinder head bolts bores, extension may be required.
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   Illustration 6	g06179971

6. Using a knot style end brush and detail cambox valley, also use correct diameter brush for lifting eye bolts.
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   Illustration 7	g06179976

7. Detail all liner bores and liner bore seats.
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   Illustration 8	g06180000

8. Detail all ends of blocks with correct wire brushes. Also, detail all threaded holes on ends of block.
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   Illustration 9	g06210352
   Typical gasket removal tooling. (D) Right Angle Die Grinder (E) ( F) ( G) Conditioning Discs, Disc Pad Holder, and Threaded Shaft

9. Remove all gasket material using die grinder with discs, scraper, Scotch Brite pad and or wire brush.
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   Illustration 10	g06179914
   View of C175 engine block installed on the 456-6500 Engine Rollover Stand.

10. Use 420-9053 Engine Block Lifting Tool to install engine block on 456-6500 Engine Rollover Stand.

11. Rotate engine block to detail all lower sides, block side bores, oil pan bores and pan rails, and inspect all threaded holes and clean as necessary.

Final Wash - Cabinet Washer and Manual Cleaning

Note: Use clean brushes, do not use the same brushes used for manual rough wash.

Internal Oil Passage Cleaning

Illustration 11	g06180003

1. Rotate block as needed for access to oil jet and main journal passages. Clean all oil jet and main journal passages using the correct nylon bristle brushes and extension when required.
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   Illustration 12	g06180320

2. Rotate block with mains facing upward, clean oil inlet passage, and all side ports using the correct nylon bristle brushes and extension when required.
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   Illustration 13	g06180332

3. Rotate block with top deck facing upward and clean all top deck passages using the correct nylon bristle brushes and extension.
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   Illustration 14	g06180339

4. Clean all turbo passages using the correct nylon bristle brushes and extension.

5. Use 420-9053 Engine Block Lifting Tool and remover from rollover stand. Position engine on clean 524-0008 Block Cribbing or wooden pallet with cylinder bores position upward.
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   Illustration 15	g06180353

6. Clean main oil galley according to Tool Operating Manual, NEHS0927, "Procedures for Using the 250-6597 Cylinder Washer Tank Group".
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   Illustration 16	g06218089
   View of oil supply lines and filter base housing (highlighted in red) on the C175-16.

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   Illustration 17	g06218094
   View of oil supply lines and filter base housing (highlighted in red) on the C175-20.

7. Clean the following oil supply lines and filter base housing (highlighted in red) that have been previously removed from the engine.

Parts and Tools for C175 Cylinder Block Cleanliness Check

Before the process is performed gather the following parts and tools.

Required Tooling & Parts

Parts

Illustration 18	g06139186
(H) 517-8261 Rear Cover Plate (J) 511-8973 Oil Spray Jet Supply Fitting (K) 511-7942 Main Bearing Oil Supply Fitting (L) 512-9374 3" Oil Inlet Canister (M) 169-7372 Fluid Sampling Bottle

Illustration 19	g06225051
(N) FT3347 Single Adapter

The FT3347 Single Adapter (N) can be used if 511-7942 and 511-8973 are not available, this is an alternate option.

Illustration 20	g06225063
(P) Contamination Filter Element Kit (Q) 561-2030 47 mm Filter Element

Fabricated Tool

One piece of steel tubing and all relevant parts must be made before starting this procedure. Use the dimensions in Table 5 to make the tool.

Note: Verify that all tooling and hose are clean after assembly.

Illustration 21	g06225078
View of fabricated wand and compression sprayer.

Flush Procedure for C175 Cylinder Block and Oil Supply Lines Cleanliness Check

The idea of this process is to help understand if the cleaning process is adequate. If any debris is found during the process, then it needs to be determined if the wash process needs improved or where the debris is coming from.

To provide addition clarification and details, a Caterpillar Channel 1 video has been created outlining the critical steps in cleanliness audit. Reviewing the video is recommended prior to flush procedure process.

Note: A CWS login is required to access Caterpillar Channel 1 Videos.

1. Ensure that the inspection fluid is clean prior to use as inspection fluid. Fluid inspection can be performed by putting a sample of fluid through the 561-2030 47 mm Filter Element and analyzing results using Table 7.
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   Illustration 22	g06139198
   (M) 169-7372 Fluid Sampling Bottle

2. Install fittings 511-7942 Main Bearing Oil Supply Fitting (K), 511-8973 Oil Spray Jet Supply Fitting (J), and fluid sampling bottles 169-7372 Fluid Sampling Bottle (M) into the main bearing oil supply holes and oil spray jet supply holes of each cylinder of the engine. The FT3347 Single Adapter (N) can be used if 511-7942 Main Bearing Oil Supply Fitting (K) and 511-8973 Oil Spray Jet Supply Fitting (J) are not available, this is an alternate option.
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   Illustration 23	g06139202
   (H) 517-8261 Rear Cover Plate (AC) 6A-5591 Bolts (AD) 131-3718 O-Ring Seal

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   Illustration 24	g06139205
   (L) 512-9374 3" Oil Inlet Canister (AC) 131-3718 O-Ring Seal (AE) 6V-6317 Bolts

3. Install a 512-9374 3" Oil Inlet Canister (L) at the oil inlet at the right rear of the block. Install 517-8261 Rear Cover Plate (H) over the main oil galley at the rear of the block.
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   Illustration 25	g06225120

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   Illustration 26	g06172735
   Collecting fluid in the cam galley

4. Start the flushing process from the top of the block through the top cam oil feed holes. A squeeze bottle or similar container can be used to flush. Collect the fluid in a container that can easily fit into the camshaft bore. Collection of all top holes should be sampled through the contamination kit (P) and the 561-2030 47 mm Filter Element (Q). Refer to Illustration 20.
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   Illustration 27	g06139226
   Side oil passage of the cylinder block

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   Illustration 28	g06225136

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   Illustration 29	g06172741
   Turbocharger supply passage

5. First flush the two side oil passages at the front of the block, refer to Illustration 27. Second flush the two turbocharger supply passages refer to Illustration 29.The fluid will drain to the main galley and accumulate in the bottles (M) and the Oil Canister (L).
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   Illustration 30	g06172727
   Camshaft passage showing oil passage to main oil galley.

6. Flush the passages from the bottom of the cam bore to the main oil galley.
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   Illustration 31	g06139232

7. Flush each cylinder head oil supply hole from the top of the block to the main oil galley.
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   Illustration 32	g06217931
   Example of finished fabricated tool.

8. Clean steel tube prior to inserting block and flushing main oil galley.

9. Remove the oil canister from the oil inlet hole. Remove the sample bottles from the mains and spray jets holes. Pour the collected liquid through the contamination filter element kit tester.

10. Analyze the 561-2030 47 mm Filter Element according to the following information. If any value exceeds any limit, rewash the block and perform the inspection again.

11. Rinse out the all sampling bottles, fittings, and containers. Remove the Cover Plate (H) from the rear of the engine and catch any fluid present. Run all fluid through the test filter element to catch any remaining debris.

12. Flush oil supply lines that have been previously removed from the engine to catch any remaining debris. Pour the collected liquid through the contamination filter element kit tester. Refer to Illustration 16 or 17 for component identification.

13. Flush the clean side of oil filter base that has been previously removed from the engine to catch any remaining debris. Pour the collected liquid through the contamination filter element kit tester. Refer to Illustration 16 or 17 for component identification.

14. Analyze 561-2030 47 mm Filter Element for the oil supply lines and oil filter base according to the following information. If any value exceeds any limit, rewash the oil supply lines and oil filter base and perform the inspection again.

Particles

Particles to be measured for size are metallic, rust, sand, and other abrasives.

Note: Abrasive materials are defines as particles exhibiting a crystalline structure and a Mohs Hardness of 6 or higher.

Typical examples of abrasives are listed below:

• aluminum oxides

• aluminum zirconium

• silicon carbides

• silicon oxide (sand)

• cubic boron nitride

• carbon carbide

• tungsten carbide

Note: Glass in the form of beads or other non-crystalline shapes are also considered abrasive particles.

Filter Element Review

Illustration 33	g06137512

1. Record the engine serial number, block part number, operator, and date.

2. View the 561-2030 47 mm Filter Elements for cleanliness using a microscope as required to measure the particle size. Record and note the particle size when applicable. 561-2030 47 mm Filter Elements should be retained or pictures taken to save a visual of the results and filed with engine rebuild documents.

3. Once audit procedure is completed, apply V.C.I. Oil or equivalent rust and corrosion preventative to the block as it will start to flash rust since it has been rinsed out.