C15 On-highway Engine BXS00001-UP(SEBP3722 - 30) - Estructura del documento Page 1 of 37

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Producto: TRUCK ENGINE

Modelo: C15 TRUCK ENGINE BXS
Configuración: C15 On-highway Engine BXS00001-UP

Pautas de reutilización y recuperación

Procedure for Reconditioning Cylinder Blocks on C-Series Engines{1201}
Número de medio -SEBF9008-02 Fecha de publicación -20/07/2007 Fecha de actualización -20/07/2007

i02619253

Procedure for Reconditioning Cylinder Blocks on C-Series Engines

{1201}
SMCS - 1201

Engine:
C-18 (S/N: CJP1-UP)
C11 (S/N: KCA1-UP)
C13 (S/N: KCB1-UP; LEE1-UP; JAM1-UP)
C15 (S/N: BXS1-UP; C5E1-UP; C5L1-UP; MHP1-UP; SDP1-UP; X4R1-UP; MXS1-UP)
C7 (S/N: KAL1-UP; JRA1-UP; JTF1-UP; FML1-UP; FMM1-UP; SAP1-UP; C7S1-UP; WAX1-
UP)
C9 (S/N: 9DG1-UP; SRB1-UP; C9E1-UP; CKP1-UP; X3R1-UP)
C18 (S/N: EJG1-UP; WJH1-UP)
Machine Engines:
C27 (S/N: DWB1-UP)
Marine Engine:
C32 (S/N: TLD1-UP)
C32 MARINE (S/N: RNC1-UP; RXB1-UP)
C7 MARINE (S/N: C7D1-UP; C7Z1-UP; C7B1-UP; C7X1-UP)
C9 MARINE (S/N: X9X1-UP; Z9X1-UP; C9B1-UP; CSN1-UP)
C15 MARINE (S/N: RLA1-UP)
C18 MARINE (S/N: CKH1-UP; C1J1-UP; NAX1-UP; NAY1-UP)
C30 MARINE (S/N: CLX1-UP)
Industrial Engine:
C11 INDUSTRIAL (S/N: GLS1-UP)
C13 INDUSTRIAL (S/N: LGK1-UP)
C15 INDUSTRIAL (S/N: JAS1-UP)
C9 INDUSTRIAL (S/N: JSC1-UP; MBD1-UP; JLW1-UP)
C15 IND (S/N: JRE1-UP)
C27 INDUSTRIAL (S/N: TWM1-UP)
Excavator:
325D (S/N: C7C1-UP)
330D (S/N: THX1-UP; THY1-UP)
365C (S/N: LHX1-UP)
385C (S/N: RHX1-UP)
Off-Highway Truck/Tractor:
773F (S/N: EHX1-UP)
777F (S/N: LJW1-UP)
Wheel Loader:
966H (S/N: RSX1-UP)
Truck Engines:
C7 TRUCK/BUS (S/N: YPG1-UP)
C9 ON-HIGHWAY (S/N: ETK1-UP)
Generator Set:

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C15 GEN SET (S/N: C5H1-UP)

C18 GEN SET (S/N: C6C1-UP; STD1-UP; STM1-UP; EKW1-UP)
C18 MARINE GS (S/N: CYN1-UP)
C9 MARINE GS (S/N: C9A1-UP)
C32 GEN SET (S/N: SXC1-UP)
Petroleum Engine:
C32 PETROLEUM (S/N: SMP1-UP)

Introduction
This Reuse and Salvage Guideline contains the necessary information in order 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 in order 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 additional information about this guideline, consult Repair Process Engineering of the Marketing &
Product Support Division at 1 (309) 675-5434.

Summary
This Reuse and Salvage Guideline describes the procedures to recondition the cylinder block for the C-Series
engines. The following procedures may need to be done when the block is reconditioned:

Inserts for the coolant passage

Inserts on the top deck

Machining of the top deck

Sleeve for the lower cylinder bore

Center mounted seats for the liner

Bearing bores

Measurements of the cylinder bore

Inspection of the crosshatch

These procedures may not need to be done when the block is reconditioned. The block should be inspected in
order to determine the procedures that are necessary. The procedures in this guideline should be used with
Reuse and Salvage Guidelines, SEBF9007, "Specifications for Cylinder Block Assemblies on C-Series
Engines".

References
ReferenceReuse and Salvage Guidelines, SEBF9007, "Specifications for Cylinder Block Assemblies on C-
Series Engines"

ReferenceCatalog, GECJ0001, "Cat Shop Supplies and Hand Tools", "Chemicals/Lubricants"

ReferenceReuse and Salvage Guidelines, SEBF8882, "Using Lock-n-Stitch Procedures for Casting Repair"

ReferenceSpecial Instruction, SEHS8919, "Salvage Procedure For Cast Iron Cylinder Blocks"

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ReferenceSpecial Instruction, REHS2133, "Cylinder Block Salvage Procedure For Using Belzona Ceramic R
Metal"

ReferenceSpecial Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R
Metal"

ReferenceCD-ROM, SERF8704, "Flame Spray Guide"

ReferenceCD-ROM, SERF8473, "Arc Spray Guide"

ReferenceReuse and Salvage Guidelines, SEBF9122, "Specifications for Cylinder Liners Measurements and
Salvage for C-Series Engines"

ReferenceReuse and Salvage Guidelines, SEBF9126, "Installing a Cylinder Sleeve in C7 Engines"

ReferenceReuse and Salvage Guidelines, SEBF8068, "Cylinder Liners"

ReferenceReuse and Salvage Guidelines, SEBF8198, "Procedure to Install Top Deck Inserts"

ReferenceSpecial Instruction, SMHS8222, "Installation of 2W-3815 Seat Insert or 5N-0093 Seat Insert "

ReferenceSpecial Instruction, SMHS7606, "Use of 1P-4000 Line Boring Tool Group "

ReferenceReuse and Salvage Guidelines, SEBF4518, "Planning Spec Areas Cylinder Blocks"

ReferenceSpecial Instruction, SEHS9031, "Storage Procedures for Caterpillar Products"

ReferenceReuse and Salvage Guidelines, SEBF8356, "Introduction to the Cleaning Guide"

ReferenceReuse and Salvage Guidelines, SEBF8357, "General Cleaning Methods"

ReferenceSpecial Instruction, SEHS8187, "Using the 6V-7840 Deck Checking Tool As "

ReferenceContamination Control Guidelines, PEBJ0002, "Caterpillar Dealer Contamination Control

Compliance Guide"

ReferenceCatalog, NENG2500, "Dealer Service Tool Catalog"

Required Tooling
Table 1

Part Number Description

1P-3537 Dial Bore Gauge Group
(1) Surface Reconditioning Pad
174-6858 Cleaner
FT-1855 Pressure Test Group
8S-2269 Ridge Reamer
5P-4175 Counterboring Tool Group
8S-3140 Counterboring Tool Group
9U-7990 (2) Counterboring Tool Group

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159-9404 Counterboring Tool Group

9U-7993 Depth Gauge As
1U-8265 Penetrating Oil
1P-5571
1P-5572 Brush
1P-5573
169-5464 Quick Cure Primer
1P-4000 Line Boring Tool Group
4C-9507 Retaining Compound
6V-7840 Deck Checking Tool As
1P-0520 Driver Gp
- 25.362 mm (0.9985 inch) End Mill
(1) For more information on removing gaskets, refer to Catalog, GECJ0001, "Cat Shop Supplies and Hand Tools", "Abrasive".
(2) Use with 9U-7988 Plate Gp

Initial Cleaning of the Engine

Illustration 1 g01339700

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

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

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.

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Always wear protective clothing and eye protection when working with
cleaning solvents.

For more information about the type of cleaning solution that should be used, refer to Catalog, GECJ0001,
"Cat Shop Supplies and Hand Tools", "Chemicals/Lubricants".

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
be the cause for early engine failure.

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

Cleaning the Cylinder Block

The cylinder block must be cleaned before being assembled. Separate the components that are made from
ferrous materials and the components that are made from nonferrous materials. The detergents that clean the
cylinder block may damage the components that are made from nonferrous material. An example is removing
the camshaft bearings before you clean the cylinder block. For more information on the types of cleaning
solutions, refer to Catalog, GECJ0001, "Cat Shop Supplies and Hand Tools", "Chemicals/Lubricants".

NOTICE
A cylinder block that is not thoroughly cleaned 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.

1. Remove the camshaft bearings from the cylinder block.

2. Place the cylinder block in a hot spray wash cabinet. Adjust the nozzles in order to efficiently clean the
cylinder block.

3. Clean all of the gasket surfaces while the gaskets are wet. Use a scraper in order to remove the majority
of the gasket. Use the surface reconditioning pad in order to remove a gasket that is difficult. For more
information on surface reconditioning pads, refer to Catalog, GECJ0001, "Cat Shop Supplies and Hand
Tools", "Abrasive".

Note: If a surface reconditioning pad was used to remove the gasket, the component must be cleaned
again. The surface reconditioning pad will contaminate the component with parts of the gasket.

4. Even though the cylinder bore has been honed, clean the cylinder bore with a nylon brush. Refer to
Table 7 for the part numbers of the nylon brushes. In order to prevent corrosion from occurring, coat the
cylinder bore with clean SAE 30W oil.

5. Use one of the following brushes in order to clean the oil passages.

 1P-5573 Brush (31.7 mm (1.25 inch))

 1P-5571 Brush (9.5 mm (0.38 inch))

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 1P-5572 Brush (19.0 mm (0.75 inch))

Top Contact Surface

Inspect and measure the top contact surface of the cylinder block.

Height of the Top Deck

The height of the cylinder block is measured from the centerline of the crankshaft bore. Use 6V-7840 Deck
Checking Tool As in order to measure the height of the top deck. Refer to Special Instruction, SEHS8187,
"Using the 6V-7840 Deck Checking Tool As " for instructions in order to use the tool. For the specifications,
refer to Reuse and Salvage Guidelines, SEBF9007, "Specifications for Cylinder Block Assemblies on C-Series
Engines".

Flatness of the Top Deck

Illustration 2 g01389075

Measure the flatness of the top deck. Use a straight edge and a feeler gauge in order to measure the flatness.
Measure the surface in two positions crosswise and measure the surface in two positions lengthwise.

Machining the Top Deck

Illustration 3 g01349139

The top deck of the cylinder block will need to be machined if the flatness of the top deck is incorrect.

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Machining the top deck will ensure that the correct flatness is obtained.

Note: If the inserts on the top deck or the inserts in the coolant passages are installed on the top deck, do not
machine the top deck until these inserts have been installed.

Coolant Passage
Inspection

Illustration 4 g01387741
Erosion around the coolant passage

Illustration 5 g01387743
Erosion around the coolant passage

Erosion can take place at the coolant passage. Do not remove the erosion by machining the top deck. Inserts

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can be installed in order to remove the erosion. Installing these inserts will minimize the amount of material
that is removed from the top deck.

Procedure

The insert should be made out of 304 stainless steel. Refer to Illustration 6 and Table 2 for the dimensions of
the insert.

Illustration 6 g01389493
(A) Thickness of the insert

(B) Chamfer

(C) Inner diameter

(D) Outer diameter

Table 2

Dimensions for the Insert for the Coolant Passage

Callout Dimension

Thickness (A)
5.50 ± 0.25 mm (0.217 ± 0.010 inch) (1)

Chamfer (B)
1.25 ± 0.25 mm (0.049 ± 0.010 inch) by 45 degrees

Inner diameter (C)

16.078 ± 0.051 mm (0.6330 ± 0.0020 inch)

Outer diameter (D)

25.400 ± 0.013 mm (1.0000 ± 0.0005 inch)
(1) Minimum dimension

1. Place the cylinder block in a drill and clamp the block in place.

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Illustration 7 g01387773

Illustration 8 g01394632
(E) Diameter of counterbore

(F) Depth of counterbore

(G) Chamfer of counterbore

2. Use a 25.362 mm (0.9985 inch) end mill in order to machine the counterbore in the coolant passage.
Refer to Illustration 8 and Table 3 for the dimensions for the counterbore.

Table 3

Dimensions for the Counterbore in the Coolant Passage

Diameter (E)
25.362 ± 0.013 mm (0.9985 ± 0.0005 inch)

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Depth (F)
5.00 ± 0.25 mm (0.197 ± 0.010 inch)

Chamfer (G)
0.8 ± 0.1 mm (0.03 ± 0.004 inch)

3. Use 169-5464 Quick Cure Primer in order to clean the counterbore.

4. Start installation of the insert by hand into the counterbore.

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

5. Apply 4C-9507 Retaining Compound to the outer diameter of the insert.

Illustration 9 g01387794

6. Use 1P-0520 Driver Gp in order to drive the insert into the counterbore of the coolant passage.

Inserts on the Top Deck for C15 through C32 Engines

Inspection

Inserts for the top deck are available at the time of rebuild if the top of the area for the cylinder liner seat
contains erosion. Erosion could be caused by heat, exhaust gases, or coolant that leaked around the liner seal.
The inserts fit into a counterbore of the cylinder bore. The counterbore must be machined into the cylinder
bore. The top of the insert will have enough clearance above the top deck of the cylinder block in order to
provide the correct liner projection.

Refer to Reuse and Salvage Guideline, SEBF8198, "Procedure to Install Top Deck Inserts" or Special
Instruction, SMHS8222, "Installation of 2W-3815 Seat Inserts or 5N-0093 Seat Inserts " for more information
regarding procedures, tooling, and dimensions.

Procedure

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Illustration 10 g01366720

Illustration 11 g01387795

1. Machine a counterbore into the cylinder bores. Refer to Table 4 for the correct dimensions for
machining.

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Illustration 12 g01369238

2. Remove all of the nicks and high spots around the counterbore. Remove all of the nicks and high spots
from the top deck.

Illustration 13 g01369247

3. Use 169-5464 Quick Cure Primer in order to clean the insert.

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Illustration 14 g01369248

4. Use 169-5464 Quick Cure Primer in order to clean the surfaces of the cylinder block.

Illustration 15 g01387797

5. Apply 4C-9507 Retaining Compound to the counterbore for the insert.

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Illustration 16 g01387798

6. Install the insert in the counterbore. The insert must be installed so the chamfer on the outer diameter is
toward the cylinder block.

Illustration 17 g01387799

7. Use the correct driver in order to install the insert. Refer to Illustration 18 for the correct driver.

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Illustration 18 g01387805
Driver for C15 through C32 Engines

Specifications for C15 through C32 Engines

The following specifications apply to C15 through C32 engines:

The insert should have a 0.07 mm to 0.10 mm (0.003 inch to 0.004 inch) press fit.

The projection of the insert above the top deck is 0.000 mm to 0.025 mm (0.0000 inch to 0.0010 inch).
Liners can then be installed with a projection of 0.025 mm to 0.152 mm (0.0010 inch to 0.0060 inch).
The liner projection must also conform with the next two specifications.

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Each liner should be measured at four 90 degree locations. The maximum permissible difference of the
four measurements cannot exceed 0.05 mm (0.002 inch).

The maximum permissible difference between the height of all liners under one head is 0.10 mm (0.004
inch).

The insert should be installed with the chamfer toward the cylinder block.

Insert Dimensions

Illustration 19 g01376122

Illustration 20 g01376123

Table 4

Machining Dimensions for the Cylinder Block

C15 through C32 Engines
Maximum Height of
Part
Projection after Bore Diameter Depth of the Chamfer or Radius
Number for
Installation of Insert (J) Counterbore (K) (L)
the Insert
(H)

6I-4361 0.025 mm to 0.152 mm 165.915 ± 0.015 0.772 ± 0.013 mm 0.25 ± 0.13 mm

(0.0010 inch to 0.0060 mm (6.5321 ± (0.0304 ± 0.0005 (0.010 ± 0.005 inch)

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inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 0.822 ± 0.013 mm 0.25 ± 0.13 mm

9Y-3368
(0.0010 inch to 0.0060 mm (6.5321 ± (0.0324 ± 0.0005 (0.010 ± 0.005 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 0.872 ± 0.013 mm 0.25 ± 0.13 mm

6I-4362
(0.0010 inch to 0.0060 mm (6.5321 ± (0.0343 ± 0.0005 (0.010 ± 0.005 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 1.555 ± 0.013 mm 0.25 ± 0.13 mm

6I-4363
(0.0010 inch to 0.0060 mm (6.5321 ± (0.0612 ± 0.0005 (0.010 ± 0.005 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 1.605 ± 0.013 mm 0.25 ± 0.05 mm

2W-3815
(0.0010 inch to 0.0060 mm (6.5321 ± (0.0632 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 1.655 ± 0.013 mm 0.25 ± 0.05 mm

6I-4364
(0.0010 inch to 0.0060 mm (6.5321 ± (0.0652 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 2.660 ± 0.013 mm 0.25 ± 0.05 mm

6I-4365
(0.0010 inch to 0.0060 mm (6.5321 ± (0.1047 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 2.710 ± 0.013 mm 0.25 ± 0.05 mm

5N-0093
(0.0010 inch to 0.0060 mm (6.5321 ± (0.1067 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 2.760 ± 0.013 mm 0.25 ± 0.05 mm

6I-4366
(0.0010 inch to 0.0060 mm (6.5321 ± (0.1087 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 169.333 ± 0.015 3.300 ± 0.025 mm 0.89 + 0.41 - 0.00 mm

108-1068
(0.0010 inch to 0.0060 mm (6.6666 ± (0.1299 ± 0.0010 (0.035 + 0.016 - 0.000
inch) 0.0006 inch) inch) inch) by 45 degrees

0.025 mm to 0.152 mm 165.915 ± 0.015 5.160 ± 0.013 mm 0.25 ± 0.05 mm

101-0524
(0.0010 inch to 0.0060 mm (6.5321 ± (0.2031 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 169.205 ± 0.015 5.080 ± 0.013 mm 0.25 ± 0.05 mm

5P-4173
(0.0010 inch to 0.0060 mm (6.6616 ± (0.2000 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

0.025 mm to 0.152 mm 165.915 ± 0.015 5.210 ± 0.013 mm 0.25 ± 0.05 mm

101-0523
(0.0010 inch to 0.0060 mm (6.5321 ± (0.2051 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

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0.025 mm to 0.152 mm 165.915 ± 0.015 5.260 ± 0.013 mm 0.25 ± 0.05 mm

101-0525
(0.0010 inch to 0.0060 mm (6.5321 ± (0.2071 ± 0.0005 (0.010 ± 0.002 inch)
inch) 0.0006 inch) inch)

Table 5

Dimensions for the Inserts

C15 through C32 Engines
Part Number for Outside Diameter (M) Thickness of the Insert
Chamfer (P)
the Insert (N)

166.000 ± 0.013 mm 0.772 ± 0.010 mm

6I-4361 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.0304 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 0.822 ± 0.010 mm

9Y-3368 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.0324 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 0.872 ± 0.010 mm

6I-4362 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.0343 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 1.555 ± 0.010 mm

6I-4363 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.0612 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 1.605 ± 0.010 mm

2W-3815 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.0632 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 1.655 ± 0.010 mm

6I-4364 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.0652 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 2.660 ± 0.010 mm

6I-4365 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.1047 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 2.710 ± 0.010 mm

5N-0093 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.1067 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 2.760 ± 0.010 mm

6I-4366 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.1087 ± 0.0004 inch)
by 45 degrees

169.418 ± 0.013 mm 3.300 ± 0.025 mm 1.31 + 0.41 - 0.00 mm (0.052 +

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(6.6700 ± 0.0005 inch) (0.1299 ± 0.0010 inch) 0.016 - 0.000 inch) by 45 degrees
108-1068

166.000 ± 0.013 mm 5.160 ± 0.010 mm

101-0524 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.2031 ± 0.0004 inch)
by 45 degrees

169.290 ± 0.013 mm 5.210 ± 0.010 mm

5P-4173 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.6649 ± 0.0005 inch) (0.2051 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 5.210 ± 0.010 mm

101-0523 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.2051 ± 0.0004 inch)
by 45 degrees

166.000 ± 0.013 mm 5.260 ± 0.010 mm

101-0525 0.5 ± 0.1 mm (0.02 ± 0.004 inch)
(6.5354 ± 0.0005 inch) (0.2071 ± 0.0004 inch)
by 45 degrees

Machine the Top Deck

Illustration 21 g01349139

The top deck of the cylinder block will need to be machined after the inserts on the top deck and the inserts for
the coolant passages are installed. Machine the least possible material from the top deck. Do not machine the
top deck out of specifications. Refer to Reuse and Salvage Guidelines, SEBF9007, "Specifications for Cylinder
Block Assemblies on C-Series Engines" for the specifications. Machining the top deck will also ensure the
correct flatness of the top deck.

Flame Spray and Arc Spray

If the top contact surface needs to be milled in order to remove any damage, the measurements must be within
original specifications. If the damage is not removed and the measurement is not within original specifications,
the cylinder block will need to be welded up to original specifications. Use the following process in order to
build the cylinder block up to original specifications.

Note: Wear a pair of clean cotton gloves when you handle the cylinder block. Contaminants will not allow the
thermal spray to bond properly.

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Illustration 22 g01349139

1. Mill the cylinder block to a minimum of 0.51 mm (0.020 inch) below the lower limit on the tolerance.

Illustration 23 g01349144

2. Apply a 1.5 mm (0.06 inch) chamfer to all of the edges of the cylinder block. Use a die grinder for the
straight edges. Use an air drill and a tool for chamfers for the holes.

Illustration 24 g01349375

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3. Plug all of the threaded holes. Plug the cylinder bores.

4. Degrease the top deck of the cylinder block.

Illustration 25 g01349376

5. Shot blast the top deck of the cylinder block immediately prior to the application of thermal spray. The
top deck of the cylinder block should have a roughness of 5.1 micrometer to 7.6 micrometer (200.00
microinch to 300.00 microinch).

Illustration 26 g01349456

6. Preheat the cylinder block to an approximate temperature of 93 °C (200.0 °F).

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Illustration 27 g01349465

7. Apply the thermal spray 0.64 mm (0.025 inch) above the upper limit on the tolerance. Apply the thermal
spray in several thin layers.

8. Mill the thermal spray so that the height of the cylinder block is between the nominal dimension and the
upper limit.

Note: The weld must have a minimum thickness of 0.38 mm (0.015 inch) in order to avoid flaking.

For additional information, refer to CD-ROM, SERF8704, "Flame Spray Guide". For additional information,
refer to CD-ROM, SERF8473, "Arc Spray Guide".

Reconditioning the Lower Cylinder Bore for C15 through C32

Engines
Inspection

Illustration 28 g01387833
Erosion in the lower cylinder bore

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Illustration 29 g01391666
Erosion in the lower cylinder bore

If the lower cylinder bore is damaged or eroded, the lower cylinder bore may need to be reconditioned.

Illustration 30 g01390320
(1) Cylinder block

(2) Sleeve

The cylinder block is machined oversize to a specified depth. A sleeve is then inserted into the oversized bore
and pressed against the step. This step allows the sleeve to be retained.

Procedure

1. Freeze 4W-6061 Bottom Liner Sleeve in order to shrink the diameter of the sleeve.

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Illustration 31 g01387836

Illustration 32 g01387837

2. Machine the lower cylinder bore to a diameter of 158.000 ± 0.025 mm (6.2205 ± 0.0010 inch) and to a
depth of 224.19 ± 0.25 mm (8.826 ± 0.010 inch).

3. Use 169-5464 Quick Cure Primer in order to clean the lower bore and the sleeve.

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Illustration 33 g01387838

4. Apply 4C-9507 Retaining Compound to the lower cylinder bore.

Illustration 34 g01388282

5. Start the sleeve into the cylinder bore.

Note: The sleeve will need to be frozen in order to shrink the diameter of the sleeve.

Illustration 35 g01388286

6. Press the sleeve into the lower cylinder bore.

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Illustration 36 g01388307

7. Machine the inside of the sleeve to 153.90 ± 0.05 mm (6.059 ± 0.002 inch).

Illustration 37 g01388308

Illustration 38 g01398414

(R) Depth of chamfer

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(S) Diameter of chamfer

(T) Angle of chamfer

8. Machine a chamfer on the top edge of the sleeve. Refer to Illustration 38 and Table 6 for the correct
dimensions.

Table 6

Dimensions for the Chamfer

Depth (R)
193.19 ± 0.25 mm (7.606 ± 0.010 inch)

Diameter (S)
158.34 ± 0.51 mm (6.234 ± 0.020 inch)
Angle (T) 25 ± 7 degrees

9. Remove any burrs or metal shavings from the sleeve after machining.

Center Mounted Liner Seats for C9 through C13 Engines

Inspection

Inspect the seat for the liner for cracks or damage. If the seat for the liner contains any cracks or damage, the
seat can be counterbored in order to salvage the cylinder block. The seat for the liner will be machined more
than the specifications. Shims are then added to the seat in order to obtain the correct depth.

Procedure

Illustration 39 g01354527

1. Measure the depth of the cylinder liner seat at four 90 degree locations with 9U-7993 Depth Gauge As .

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Illustration 40 g01354542

2. Position the counterboring tool in the cylinder bore and secure the tool with bolts. Make sure that the
cutting plate rotates freely.

Note: Use of 1U-8265 Penetrating Oil will help the cutting plate rotate freely in the cylinder bore.

Illustration 41 g01354547

3. Adjust the cutting plate by rotating the two set collars on the tooling.

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Illustration 42 g01354548

4. Cut the counterbore. Maintain a constant down pressure on the tooling while the counterbore is cut.

Illustration 43 g01354527

5. Remove the counterboring tool and measure the depth of the cylinder liner seat.

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Illustration 44 g01354554

6. Install shims into the cylinder bore in order to achieve the correct depth.

Bearings and Bores

Inspection

During the disassembly of the engine, inspect the main bearings and the camshaft bearings. Excessive wear in
the bearings during a short period of time may be the result of a blocked oil passage. If necessary, inspect the
oil passages.

Inspect the bore for the main bearings. Inspect the main bearing cap. Use a dial bore gauge in order to measure
the bore. If necessary, the bore for the main bearings can be machined in order to accept oversized bearings.
Refer to Reuse and Salvage Guidelines, SEBF9007, "Specifications for Cylinder Block Assemblies on C-
Series Engines" for the specifications and procedures on measuring the bore for the main bearings. For part
numbers of the oversized bearings, refer to the Parts Manual for your engine.

Inspect the bore for the camshaft bearings. Use a dial bore gauge in order to measure the bore. Refer to Reuse
and Salvage Guidelines, SEBF9007, "Specifications for Cylinder Block Assemblies on C-Series Engines" for
the specifications and procedures on measuring the bore for the camshaft bearings.

Inspect the alignment of the main bearing bores. Use a boring machine in order to check the alignment of the
main bearing bores. If a boring machine is not available, use a long machinist's straightedge and a feeler gauge
in order to check the alignment of the bearing bores. The following procedure describes the use of a
machinist's straightedge and a feeler gauge in order to check the alignment:

Place a 0.038 mm (0.0015 inch) feeler gauge in the bore and then lay the straightedge across the feeler
gauge and several of bearing bores. Do not put pressure on the straightedge.

Check if the feeler gauge pulls out freely. If the feeler gauge pulls out freely, that bore is not in
alignment.

Use this procedure in order to check the alignment of each main bearing bore.

Note: The machinist's straightedge must be handled carefully in order to prevent nicks and burrs. Support the
cylinder block evenly so the measurements are accurate.

Procedure

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Use 1P-4000 Line Boring Tool Group or a suitable machining center in order to line bore the cylinder block.
Refer to Special Instruction, SMHS7606, "Use of 1P-4000 Line Boring Tool Group " for more information
about this tool.

Refer to Catalog, NENG2500, "Dealer Service Tool Catalog" for the correct centering rings that are used for
the procedure.

Follow the procedure in Special Instruction, SMHS7606, "Use of 1P-4000 Line Boring Tool Group " and use
the centering rings that are listed in Catalog, NENG2500, "Dealer Service Tool Catalog".

Illustration 45 g01370431
(3) Centering ring

(4) Oiler

Place the centering rings on either side of the cap that is being replaced. Verify that the oilers are facing
upward. For an end cap, place the centering rings in the bearing bores that are next to the bearing bores on the
end.

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Illustration 46 g01370432
(3) Centering ring

(5) Original bearing cap

(6) Bolt

(7) New machined cap

In the procedure for setting up the boring bar, tighten the bolts on the bearing caps that have centering rings
from a minimum of 27 N·m (20.0 lb ft) to a maximum of 70 N·m (52.0 lb ft). Rotate the boring bar in order to
check for binding. All other bearing cap bolts should be tightened to the specifications in the service manual.

Place the cutting tool in the holder, and set the micrometer 1.78 mm (0.070 inch) less than the finished bore
diameter in order to set the tool bit.

Note: This setting may change for a standard or an oversized centering ring. Verify the dimensions after
machining has occurred and before the bearing caps are removed.

Cylinder Bores
The cylinder bores for the C-Series engines must meet the original specifications of the engines.

The C7 engine does not have cylinder liners. The remaining sales models have cylinder liners. For more
information about cylinder liners, refer to Reuse and Salvage Guidelines, SEBF9122, "Specifications for
Cylinder Liner Measurements and Salvage for C-Series Engines".

Cleaning, Measuring, and Honing the Cylinder Bores

Illustration 47 g01162360
Typical example of the nylon brush that is used to clean the cylinder bores

Use a nylon brush in order to clean the cylinder bores. Clean the cylinder bores before measuring in order to
ensure an accurate measurement. Refer to Table 7 for the part numbers of the nylon brushes.

Table 7

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Sales Model Brush

C7 1U-7429
C9 1U-7429
C10 1U-9788
C11 1U-9788
C12 1U-9788
C13 1U-9788
C15 4C-6345
C18 4C-6345
C27 4C-6345
C32 4C-6345

Illustration 48 g01162351
1P-3537 Dial Bore Gauge Group

In order to measure the inside diameter of the cylinder bores, use a dial bore gauge.

Illustration 49 g01354565

Measure the cylinder bore parallel to the crankshaft. Measure the cylinder bore at a right angle to the
crankshaft. Measure the cylinder bore at the top, the middle, and the bottom. The areas of the cylinder bore

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that receives the most wear is at the top and the bottom of ring travel.

Note: The C7 engine will require a cylinder head stress plate and a cylinder head gasket when you measure the
cylinder bore. The C7 engine requires a cylinder head stress plate and a cylinder head gasket when you are
honing the cylinder bore.

The following cylinder head stress plates are for the C7 engine:

142-2285 Cylinder Head Stress Plate

125-2064 Cylinder Head Stress Plate

If the size of the cylinder bore on the C7 does not meet new specifications, a 107-7604 Cylinder Sleeve may be
installed. Refer to Reuse and Salvage Guideline, SEBF9126, "Installing a Cylinder Sleeve in C7 Engines".

The sleeves in the C7 engines must be honed in order to obtain the correct crosshatch. Refer to Reuse and
Salvage Guideline, SEBF9126, "Installing a Cylinder Sleeve in C7 Engines" for the correct honing procedures.

Inspecting the Crosshatch

Engine Repair

Repair - Required engine service due to a failure

Inspect the cylinder bore for the crosshatch.

If variations in the crosshatch exist, measure the bore with 1P-3537 Dial Bore Gauge Group .

If the cylinder bores meet specifications, run the engine until the time of engine rebuild.

If the cylinder bores do not meet specifications, install sleeves in the C7 engine or install new liners in
the C9 through C32 engines.

Engine Rebuild

Rebuild - Completely overhaul the engine at a scheduled service interval.

Inspect the cylinder bore for the crosshatch.

The cylinder bores must have at least 75% or more of crosshatch.

If the crosshatch does not meet specifications, install sleeves in the C7 engine or install new liners in the
C9 through C32 engines.

Miscellaneous Repairs
Threaded Holes and Cracks

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Illustration 50 g01346083

Inspect all of the tapped holes. Tapped holes that are damaged can be repaired, even if the tapped holes extend
into the cooling passages.

Illustration 51 g01346084

Inspect the cylinder block for any cracks. If the cylinder block is cracked, the cylinder block can be repaired.
For more information on repairing cracks, refer to the ""Lock-n-Stitch" " section in this guideline.

Lock-n-Stitch

Lock-n-Stitch is the preferred method for repairing a failure in a cylinder block. Kits are available from
Caterpillar and kits are available directly from Lock-n-Stitch. Lock-n-Stitch can be contacted by using the
following information:

http://www.locknstitch.com/

1015 S. Soderquist Rd.

Turlock, CA
95380
209-632-2345800-736-8261

Lock-n-Stitch repair kits are available from Caterpillar. The kits are used to repair single failures that are
caused by a connecting rod. The kits are also used to repair cracks that are in a casting. These repairs should
not be made in structural areas. The repair method that is utilized can achieve a permanent repair. The detailed
instructions and the part numbers for the kits can be found in the Reuse and Salvage Guidelines, SEBF8882,
"Using Lock-n-Stitch Procedures for Casting Repair".

Cast Iron Welding

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Depending on the type of weld that is required, cast iron cylinder blocks can be welded. Welding cast iron
requires preheating. For more information on welding cast iron, refer to Reuse and Salvage Guidelines,
SEBF8882, "Using Lock-n-Stitch Procedures for Casting Repair" and Special Instruction, SEHS8919,
"Salvage Procedure for Cast Iron Cylinder Blocks".

Belzona Ceramic Metal

Belzona can be used to repair porosity or pitting of the cylinder block. Instructions for obtaining the material
and for the application of material can be found in Special Instruction, REHS2133, "Cylinder Block Salvage
Procedure for Using Belzona Ceramic R Metal" or Special Instruction, SEHS8869, "Cylinder Block Salvage
Procedure for Using Belzona Ceramic R Metal".

Storage Procedures
Proper protection of the cylinder blocks from corrosion is very important. Corrosion will start in as little as one
hour after the cylinder blocks have been exposed.

Illustration 52 g01339742

When the cylinder blocks will not be inspected for one hour or less the cylinder blocks should be coated with a
rust or corrosion inhibitor or coated with clean engine oil. The cylinder blocks should be individually wrapped
in order to prevent contamination, and the cylinder blocks should be stored in a protected area in order to avoid
damage.

When the cylinder blocks will not be inspected in two days or more the cylinder blocks should be coated with
a rust or corrosion inhibitor or coated with clean engine oil and the cylinder blocks should be individually
wrapped. The wrapped cylinder blocks should be placed in a container which is clean and structurally solid.
The container should be covered or wrapped in plastic in order to prevent damage and contamination to the
cylinder block. See Illustration 54.

See Table 8 for recommended rust inhibitors.

Illustration 53 g01391702

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Example of protection for a component that is stored for a shorter term

Illustration 54 g01391703
Example of protection for a component that is stored for a longer term

Table 8

Recommendations for Storage

Part Number Quantity Description Storage Protection
Hard Film
355 mL
222-3121 (12 oz.) Rust Preventive Up to one year storage
Aerosol
Outside conditions for storage

1U-8809 One year storage

3.79 L (1 US gal)
Caterpillar Rust Preventive Oil
1U-6523 Covered conditions for storage
208 L (55 US gal)
Film of wax
1U-8801
3.79 L (1 US gal) Up to one year storage
Caterpillar Rust Preventive Oil
1U-6526 Outside conditions for storage
208 L (55 US gal)

Copyright 1993 - 2009 Caterpillar Inc. Tue Mar 17 10:55:35 EST 2009
Todos los derechos reservados.
Red privada para licenciados del SIS.

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