All 4.75″ (120.6) Bore Engines With 2 Valves Per Cylinder
Replacement thrust plates are available for the crankshaft of both the counterbored cylinder blocks, and the spacer plate cylinder blocks of the 4.75″ (120.6) bore engines given above. This instruction gives a method to find which thrust plates to use, when it is necessary to make a replacement. Measure the width of the rear main bearing journal, then make reference to the chart on page 2, to find which thrust plate is needed.
NOTE: Always install the thrust plates so the words “BLOCK SIDE” are next to the cylinder block.
Measure width (A) of the rear main bearing journal of the crankshaft. Make reference to the dimensions in the chart to find the correct thrust plates to install.
Engine: 3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All All 3500 Engines All 3600 Engines All C280 Engines C-10 All C-9 and C9 All C11 All C12 and C-12 All C13 and C-13 All C15 and C-15 All C16 and C-16 All C175 Engines C18 and C-18 All C27 All C32 All C4.4 Engines C6.6 C7 All C7.1
|Revision||Summary of Changes in SEBF9243|
|05||Added new serial number prefixes.|
Updated Safety Section
|01 – 03||Updated Effectivity|
© 2014 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 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:
- Caterpillar Dealer Technical Communicator
- Dealer Solution Network
- Caterpillar Technical Representative
- Knowledge Network
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
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 in order 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 specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should 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.
To reduce the risk of leaks and failures, it is important that crankshaft seals are properly installed. Proper operation of a crankshaft seal is dependent on many factors such as:
- Cleanliness of the seal, tooling, and all other mating components.
- Appropriate protection and handling of the crankshaft seal.
Mating Component Storage
Crankshafts and housings should be stored in a manner that will reduce contamination and damage to the sealing surfaces. Storage should also conform to the Cat dealer Contamination Control Compliance Guide (PEBJ0002).
Mating Component and Tooling Cleanliness
The housings, crankshafts, and all installation-related items must be free of all contamination. The housing bores and crankshafts must be free of scratches, nicks, dents, or any other feature that will compromise sealing.
Each housing bore and shaft should be wiped clean with a lint-free wipe before installation.
Handling of Crankshaft Seals
Some crankshaft seals arrive with a supplier-applied sealant around the outer diameter of the seal case and/or the inner diameter of the wear sleeve. This coating will typically be red, blue, or green depending on the supplier and seal location. This coating is critical for sealing against the bore and shaft, and must not be scratched or removed from the seal.
|Proper crankshaft seal handling.|
To avoid contamination, seals should be handled only by touching uncoated metal surfaces whenever possible. To reduce the risk of damage, never touch the seal on the sealing surface. If necessary, seals may be carefully handled on coated metal surfaces. Ensure that the coating does not get scratched nor contaminated.
|(1) Wear sleeve
(2) Sealing lip
Some seals are supplied with a plastic sleeve around the interior diameter. The sleeve holds the PTFE (Polytetrafluoroethylene) sealing lips in place and the sleeve protects the seals from damage. Once this plastic sleeve has been removed, the PTFE sealing lips will begin to relax. If the PTFE sealing lips relax, the seals will prevent proper installation. These plastic sleeves must only be removed during or immediately before installation.
Assembly areas should have procedures for inspection and cleaning of seal installation tooling. Areas of special importance include:
- Any damage to the installation tooling that could damage the crankshaft seal diameter face.
- Any malfunction of the hydraulic or pneumatic press supply pressure or pressure regulator.
- The piloting features of the tool must be square and free from damage. Inspect the ram inside the press for damage or excessive wear.
If any of the above occurs, the seal may be damaged or will not be seated correctly. If damage is observed or noted, then immediately stop using the tool. Notify the appropriate dealer personnel to report the damage.
Tooling Maintenance and Damage Reporting
Routine Maintenance – All seal-specific tooling should be placed on a routine maintenance schedule similar to the torque-tooling schedule.
Reporting Damage – A formal reporting process shall be established at every dealer to report damaged tooling.
Tooling storage surfaces will be clean and free from contamination.
Preassembly Inspection of Critical Components
Complete a brief inspection for seal and mating components for damage and contamination. This inspection is to provide a brief visual review of the part and mating component for damage or debris. This inspection is to help identify part issues before assembling the parts to the components.
Complete a visual inspection to verify the presence of the spring in crankshaft lip seals.
Before installation of the crankshaft seal and the wear sleeve, inspect the crankshaft for scratches. Also, inspect the crankshaft for any distortion on the surface that may lead to an out of round condition. Use a polishing cloth to remove any slight imperfections on the crankshaft.
Do not lubricate crankshaft seals. Crankshaft seals are intended for dry installation. Neither the sealing lip or the journal should be lubricated.
Apply Loctite sealant to the seal outside diameter and/or the wear sleeve inside diameter if either surface does not have supplier applied coating.
Refer to “Loctite Maintenance and Solutions Heavy Equipment Guide for Cat Dealers” for a list of sealant part numbers and the application for use. This document can be downloaded at:
Also refer to “Doing it Right Loctite User’s Guide” for the best application of Adhesives and Sealants. This document can be downloaded at:
Assembly Tooling Use
Use the correct seal assembly tool as specified in the proper Disassembly and Assembly Manual. Follow the tooling inspection and care processes during assembly.
All crankshaft seals require either a wear sleeve or installation sleeve for assembly regardless of the shaft. The sleeve prevents the seal lip from relaxing and being folded under during assembly.
3300 Family Of Engines
Oversize main bearings are being used in the short blocks of Remanufactured 3300 Engines. These bearings are also available for parts service when overhaul or repair of these engines is required. The bearings are available in the following two sizes.
4P7305 Main Bearing: 0.51 mm (.020″) oversize OD, 0.51 mm (.020″) undersize ID.
4P7306 Main Bearing: 0.51 mm (.020″) oversize OD, 0.76 mm (.030″) undersize ID.
- 3500 Family Pumpers
- 3500 and 3500B Family Generator Sets and Power Modules with Standard Displacement
- Engines with ACERT Technology
- Equipped with Air CompressorsCaterpillar Products: All
- 3500B EnginesCommercial and Truck Engines:
- C-16Electric Power Generation:
- AllEngine: Commercial
- 3500 and 3500B Family All
- All Diesel
- G3500 Family AllEngine: Industrial, Marine, and Generator Set that Use Flash Programming
- AllEngine: Marine
- 3500 SeriesEngine: Truck
- All Commercial Gas Engines
- G3600Industrial Engine: with Turbochargers
- AllMarine Engine: with Turbochargers
- AllPumper: All
- Utility Mounted
Illustration 1 g01206787
Illustration 2 g01206759
Dealer Service Tools now offers the 262-8390 Microscope for inspecting the bearing journals on the engine crankshafts for all Caterpillar machine and engine products. The new microscope is recommended for checking the journal surfaces after a magnetic inspection has been performed. This 40 power microscope is a good general usage instrument that is equipped with a light. The microscope’s reticle indicates in 0.5 mm (0.02 inch) increments for accurate measurements. The 262-8390 Microscope replaces the 6V-2196 Microscope and the 6V-7894 Microlite which are cancelled.
Cleanliness is a major factor in preventing bearing failures. Do not assemble debris into the engine. Successful overhauls demand clean work areas and clean components for assembly. It is important that the correct procedures and tools are used to achieve the desired cleanliness.
Cleanliness must start with the disassembly of the engine. First, use a steam cleaner or similar equipment to clean the external surface of the engine. This will help keep the assembly area clean and reduce the chance of contamination in an assembled engine. Use plastic plugs and covers to prevent debris from entering the disassembled engine components. Use the correct tools, lifting devices and storage racks to avoid damage and protect the engine components.
One reason for bearing failure after an engine overhaul is debris that was not removed from the oil passages in the crankshaft and cylinder block. Some of this debris (carbon deposits or sludge) is a product of fuel combustion that, over a long period of time, mixes with oil and becomes thick.
Another source of debris is metal chips or abrasive material that is not removed after an engine or bearing failure or after a reconditioning operation. This debris can cause damage to the bearing journals and bearings when the engine is first started.
Extra care must be taken after a bearing failure to make sure all the debris and bearing material is removed from the entire engine lubrication system. The crankshaft oil passages must be cleaned. All plugs, orifice dowels, cooling jets and hoses must be removed from the block so the oil passages can be cleaned. Remove auxiliary equipment that is lubricated by the engine oil. Disassemble this eqiupment and clean the oil passages.
It is important that all debris is removed from the oil passages in the crankshaft and cylinder block. Cleaning must be complete and thorough, because cleaning that is not thorough may only result in loosening debris, allowing it to break free and damage bearings and other components after the engine is put into service.
Oil passages must be thoroughly cleaned with brushes to make sure all carbon deposits (sludge) and debris are removed. Good quality brushes are required. The following brushes are available from Caterpillar and are in sizes that will clean all current engine blocks and crankshafts.
NOTE: When the main oil passage in the cylinder block is cleaned, it will be necessary to weld a 3.18 mm (.125″) mild steel rod to the end of the brush handle. Make sure the rod is long enough to let the brush go all the way through the cylinder block. See Illustration 1.
Illustration 1. Weld a steel rod to brushes used to clean long passages such as the main oil gallery in cylinder blocks.
Most of the time debris can not be removed completely when only a high pressure wash or a high pressure nozzle is used to clean the oil passages. A nozzle with a high aerated flow or pulsating flow is recommended. One aerated nozzle that can be used is the “Jumbo Jiffy Gun” with “Air Boost.” Parts for this tool are shown in the chart that follows. These parts are available from:The Elliott Company
1809 Sheridan Avenue
Springfield, OH 45505 U.S.A.
Telex: (810) 452-2865
Telephone: (513) 324-4191
Use a 2 to 3% (by volume) alkaline type cleaning solution (detergent) with the cleaning gun (aerated nozzle). The temperature of the cleaning solution must be 43 to 55°C (110 to 150°F).
Special Instructions will be available to give more detailed information about the cleaning equipment and procedures.
Cleaning Procedure For Cylinder Blocks And Crankshafts
Caterpillar recommends to use the procedure that follows to clean the oil passages in all new, used and reconditioned crankshafts and cylinder blocks.
1. Use steam cleaning or a similar method to remove as much external dirt, oil or preservative coating as possible.
2. Remove all covers and plugs from the oil passages. See Guideline For Reusable Parts, Visual Inspection Of Crankshafts, Form SEBF8043 for information about crankshaft plug removal.
3. Position cylinder blocks upside down (oil pan rails up).
4. Use a petroleum base cleaning solvent and the correct size brush in a variable speed drill to loosen debris or carbon deposits (sludge) in all crankshaft or cylinder block oil passages. Operate the drill at approximately 300 rpm. The diameter of the brush must be slightly larger than the diameter of the oil passage that is to be cleaned. Make sure the end of the brush goes to the end of each oil passage. Each oil passage must be cleaned vigorously and repeatedly from every possible direction.
5. After most of the debris has been removed using the brush and petroleum base cleaning solvent, use the brush and a solution of detergent and water to clean out all visible debris.
6. After brushing, use the aerated nozzle (“Jiffy Gun”) and hot alkaline type cleaning solution to clean and flush all debris from the oil passages.
7. Flush auxiliary passages toward the main oil gallery, then flush the main gallery from one end. Flush all main galleries such as the camshaft bores in a similar manner. Always flush out the main galleries last, to wash away debris flushed from the auxiliary passages.
8. One major source of debris that is not obvious is small metal particles that are created when pipe plugs and other plugs are installed. The following procedure will reduce the dangers from this source.
a. Clean the cylinder block or crankshaft first with all plugs removed.
b. Use a small brush to clean the threads of each plug and tapped hole; use detergent and water. If threads are damaged or have burrs, use a tap to clean and repair them. Then clean the threads and passages again with a brush and use the aerated nozzle (“Jiffy Gun”) to flush the passages.
c. Install all plugs in the crankshaft and cylinder block. Be sure the correct plugs are used. Tighten each plug to its correct torque. See the appropriate Service Manual module.
d. Repeat flushing of the main galleries (after the plugs are installed) with the aerated nozzle and cleaning solution to remove particles caused by installation of the plugs. (Although auxiliary passages can only be flushed from one end, this operation will usually be adequate and better than not flushing after the installation of the plugs).
9. Use clean water under pressure to flush the rest of the detergent and water solution out of the oil passages. Then use air pressure to dry the cylinder block or crankshaft. (Do not allow surfaces to dry by evaporation. Corrosion and rust are more likely).
10. If the crankshaft or cylinder block is not to be used immediately, flush the oil passages with clean oil and put plastic plugs in all oil passage openings. Put a rust inhibitor over the complete cylinder block or crankshaft. Put the crankshaft or cylinder block in VCI (volatile corrosion inhibitor) storage bags for long term storage (more than 30 days). For more information about rust inhibitor materials, contact the local Caterpillar Dealer.
11. Before a crankshaft or cylinder block (that is new or has been in storage) is put into service, be sure to remove all plastic plugs and rust inhibitor. Flush out the oil passages. Then dry and lubricate as necessary before installation.
It is very important for an engine to have adequate (needed) lubrication during the first seconds of operation. A “dry start” (without needed lubrication) of an engine can cause bearing damage. An engine generally has enough oil on the parts for lubrication during engine start-up; however, this lubrication may not be enough or may be lost if the engine has been in storage for any length of time. To prevent the possibility of a “dry start” and bearing damage during the first seconds of operation, pressure lubrication of the engine is necessary (fill the main oil passages with oil under pressure).
Special Instruction, Form SMHS7701, gives the pressure lubrication procedure for engines.
It is essential to bearing performance that the lubrication system be maintained properly. This maintenance will help keep the oil clean and free of contamination. Correct maintenance includes …
- … using oil of the correct grade and viscosity
- … maintaining the correct oil level
- … adhering to the recommended oil and filter change intervals
- … using the correct oil filter; one known to be high quality
The appropriate Operation and Maintenance or Lubrication and Maintenance Guide will give recommendations for oil grade, viscosity and change intervals. Use of the correct Caterpillar filter is the best way to make sure filter performance is satisfactory.
There have been reports of direct injection engines experiencing brief opposite rotation of the crankshaft. There are several conditions which can lead to opposite rotation of the crankshaft. Most of these conditions occur when there is excessive engine load at low idle rpm. Opposite crankshaft rotation is also more likely to occur after the engine reaches operating temperature.
Here are some examples of conditions which could cause opposite crankshaft rotation.
- 1. The engine is made to lug excessively at low idle rpm by suddenly increasing the load from either the hydraulic system or drive train. Hydraulic control systems normally have a check valve between the pump and the implement to prevent reverse oil flow to the pump. However, residual pressure in the hydraulic system can briefly become greater than the torque available from an engine lugged at low idle rpm. When this happens, a force goes through the hydraulic pump in the opposite direction.
- 2. Engine cranking is interrupted before full cranking speed is reached. This is sometimes called “bump starting”. It causes compression in the combustion cylinders and “kicks” the crankshaft in the opposite direction. Bump starting with a load on the engine can increase the chances of opposite crankshaft rotation.
- 3. If the machine is in a forward speed and goes in a reverse direction (backs) down an incline, the momentum in the reverse direction can be greater than the available engine torque. This can briefly turn the crankshaft in the opposite direction.
- 4. The low idle rpm is below specifications.
- 5. The engine turns slowly when being started due to low battery charge or poor battery connections.
To reduce the chances of having opposite crankshaft rotation, Caterpillar recommends the following:
1. Make sure that all operators are warned against lugging the engine at low idle rpm.
2. Discourage operators from shifting from a forward speed to reverse while the vehicle is in a forward direction.
3. Instruct operators to bring the engine rpm to full cranking speed before the starting mechanism is disengaged.
4. Discourage operators from using a forward gear to brake the machine as it goes in a reverse direction down an incline, especially if the engine is in low idle rpm.
5. Adjust low idle rpm to meet specifications.
6. Make sure that batteries and starting system connections are in satisfactory condition to give full cranking power to the starter.
If opposite crankshaft rotation does occur, Caterpillar recommends the following actions:
1. Shut the engine off immediately.
2. Inspect the air cleaner elements for damage or plugging. Replace if necessary.
3. Restart the engine and observe the oil pressure. If it is normal, operate the engine for five minutes. Shut off the engine, replace the oil filter, and inspect the used oil filter for any evidence of engine bearing damage.
4. Take an engine oil sample for analysis.
5. Take an engine oil sample for analysis every 50 hours of operation until the next scheduled oil change.
3304 and 3306 Engines
There are four crankshaft rear seals available for use on 3304 and 3306 Engines. Two of the seals are used with a wear sleeve and the other two seals are not used with a wear sleeve. The chart that follows shows which crankshaft rear seals use a wear sleeve and which do not. Check the Parts Book to see which crankshaft seal is needed for your engine.
Special Instruction Form Number SMHS7100 is available for installation instructions on crankshaft seals and wear sleeves.
Check Crankshaft Seals During Installation Of Engine Overhaul Gasket Kits; Add A Wear Sleeve When Needed
3304, 3306 Engines In All Applications
Some basic overhaul gasket kits have a crankshaft rear seal for use with a wear sleeve, but the wear sleeve is not part of the kit. One example is the 9S3366 Basic Overhaul Gasket Kit, which has a 9S3111 Seal but does not have the 2P3858 Wear Sleeve. The wear sleeve was not made a part of the gasket kit because replacement of the sleeve is not necessary on every engine where the gasket kit is used.
This principle has caused some problems for servicemen, and will be changed as new gasket kits are released. The former overhaul kits will be canceled, and separate kits used for different areas of the engine. The new kits for the engine “rear structure”, which have the crankshaft rear seal, will also have the wear sleeve.
Until the new gasket kits are available, be sure to check the crankshaft seals during installation of engine overhaul gasket kits, and use a wear sleeve when needed on a specific engine. The chart that follows shows the different crankshaft seals used on 3304 and 3306 Engines, the seal type, and which seals are used with a wear sleeve. Special Instruction, Form SMHS7100, is available with information to install seals and wear sleeves.
All Caterpillar Engines
A new bend specification of 0.13 mm (.005″) maximum T.I.R. (Total Indicator Reading) for main bearing journals is to be used for both used and field reground crankshafts. This new specification is to be used when a crankshaft is measured according to the “Guideline For Reusable Parts-Procedure To Measure Bent Crankshafts,” Form No. SEBF8030-01. Make a note of this change in the above publication.
A future revision will have this change.
Publication Date -13/08/1980