Caterpillar Engines Troubleshooting | Cat Engines Maintenance & Repair Guides - Part 2

New 6V7059 Micrometer Measures Liner Top Flange And Valve Lip

A 6V7059 Multiple Anvil Micrometer is now available. The new micrometer can be used to measure the thickness of cylinder liner top flanges and engine valve lips. It can also be used to measure parts that do not fit a standard micrometer. The micrometer has two anvils that can be removed. These anvils will measure areas not possible to measure with a standard micrometer.

Before you use a cylinder liner again, measure the thickness of the top flange. The minimum thickness for a cylinder liner top flange is in the Specifications Module of the Service Manual.

Check liner projection at assembly as described in the Service Manual.

If you use the micrometer with a 6V2034 Adapter it will measure engine valve lips. Accurate measurements are important if you want to use the valve again. Minimum valve lip thickness dimensions are in the Guideline for Reusable Parts – Valves and Valve Spring Specifications, Form SEBF8034-03.

The 6V7059 Micrometer can be used on all Caterpillar cylinder liners and all Caterpillar engine valves with 30° and 45° valve faces. It can also be used as a general purpose 0 to 25 mm micrometer.


Use the 6V7059 Micrometer with a 6V2034 Adapter to measure the thickness of a valve lip.

22. May 2018 by sam
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Use FT1711 Light Table For Cylinder Liner Inspection

Cylinder liner inspection can be made easier with the FT1711 Light Table. Defects can not always be seen on the internal surface of a liner when a flashlight or ceiling light is used. Larger cylinder liners are very heavy, and difficult for the serviceman to hold up to the light source.

The new FT1711 Light Table can hold up to six cylinder liners at a time on a sheet of Plexiglass over a fluorescent light source. The table can also be adjusted to different angles for better inspection of the internal surfaces of the cylinder liners. This will decrease inspection time. The new light table can be used to inspect all cylinder liners up to 6 1/4″ bore size.

Drawings needed to fabricate the FT1711 Light Table are available from your Division Service Manager.

The FT1711 Light Table.

22. May 2018 by sam
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Procedure To Clean Oil Passages In Crankshafts And Cylinder Blocks

All Engines

It is Caterpillar’s recommendation that the procedure that follows should be used to clean all new, used (crankshafts and cylinder blocks that are to be used again) and reconditioned crankshafts and cylinder blocks before they are assembled.

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) is a product of fuel combustion that, over a long period of time, has mixed with oil and become thick. Most of the time this debris can not be removed completely when only a high pressure wash or a high pressure nozzle is used to clean the oil passages.

Debris (chips or abrasive material from the reconditioning operation) that is not removed after an engine or bearing failure or after a reconditioning operation can also cause early engine failure. It is important that all debris is removed from the oil passages in the crankshaft and cylinder block. Larger particles of debris can cause damage to the crankshaft journal and bearings when the engine is first started because the bypass valve can let unfiltered oil get in to the engine. See Illustration 1.

Illustration 1.

Use the following procedure to make sure the oil passages in the crankshaft and cylinder block are free of debris:

1. Remove all plugs. Allen head plugs may have to be drilled and removed with a 6.35 mm (.25″) Easy Out Remover. Most lightening hole core plugs are held in position with snap rings. These snap rings can be removed with two screwdrivers or can be cut in half with a cold chisel. Cylinder block plugs and similar plugs in older crankshafts can also be removed with a cold chisel.

2. Install one of the brushes from the chart in a variable speed drill. Use a brush that has a diameter that is just larger than the diameter of the oil passage to be cleaned.

3. Use a petroleum solvent and one of the brushes from the chart to loosen any debris or carbon (deposits) in all the oil passages in the crankshaft and cylinder block. See Illustration 2. Make sure the end of the brush goes to the end of each oil passage. Each oil passage must be cleaned from every possible direction. 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 3.

Illustration 2.

Illustration 3.

4. Use the brush and a solution of detergent and water to “float” the debris out of the oil passages. Use water to wash the rest of the detergent and water solution out of the oil passages and then use an air hose to dry the cylinder block or crankshaft.

22. May 2018 by sam
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Procedure To Salvage 4.75″ Bore Cylinder Blocks

1. Counterbore the damaged area until the fretting, corrosion, cracks, or worn step on top of the block under the liner flange is removed.

2. Measure the depth of the counterbore and select the next thickest shim. Use only ONE new shim per cylinder. Do NOT reuse an old shim or stack of shims.

3. Continue machining the counterbore to a depth that will adjust the liner projection to the height of the other cylinders.

4. If all of the cylinders are counterbored, adjust the liner projection to the projection shown in the Service Manual.

22. May 2018 by sam
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Use Only Stainless Steel Cylinder Liner Shims To Salvage Damaged 4.75″ Bore Cylinder Blocks

3300 Family Of Engines

Reference: Special Instruction; Form FM055228-03; “Using 8S3140 Cylinder Block Counterboring Tool Arrangement” for All Caterpillar Engines With Cylinder Liners; Page 15.

Only stainless steel cylinder liner shims are recommended for salvage operations on 4.75″ bore cylinder blocks. A shim is defined as: “A stamped steel spacer which is not machined flat on both sides.” Cylinder blocks which show signs of wear or damage (fretting, corrosion, cracks, or a wear step on top of the block under the liner flange) can be repaired. Previously, it was recommended to use the 8S6045, 8S6046, 8S6047, 8S6048, or 8S6049 Cylinder Liner Shims (steel), for salvaging the cylinder block. This is mentioned in the Service Manual and the Reference. However, it is now recommended to use ONLY the stainless steel cylinder liner shims mentioned in this article.

To salvage a worn or damaged cylinder block, see the Reference, and follow the “Procedure To Salvage 4.75″ Bore Cylinder Blocks” in this article. See the chart for the stainless steel cylinder liner shims available.

NOTE: Use ONLY stainless steel cylinder liner shims to salvage 4.75″ bore cylinder blocks. Shims (of any material) are NOT recommended to adjust the liner projection in the 3300 Family Of Engines.

 

Publication Date -01/12/1990

22. May 2018 by sam
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Oversize Main Bearings Used In Remanufactured Engines Are Also Available For Parts Service

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.

Publication Date -01/05/1991 Date Updated -01/05/1991

22. May 2018 by sam
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Be Sure To Use Correct Cup Plugs On OR2077, OR2554, And OR3258 Remanufactured 3304 And 3306 Short Blocks

Some Remanufactured 3304 and 3306 short blocks are built with block castings that have two core plug openings on the left side of the block. These openings are sealed with 3S8313 Cup Plugs. Most parts books do not show the location of these plugs. The illustration shows the location of the plugs.

Location of 3S8313 Cup Plugs. (Right Side View Of Cylinder Block) The other 3S8313 Cup Plug is at the same height and on the same side of the block, but approximately the same distance from the other end of the block.

Publication Date -01/11/1992

22. May 2018 by sam
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Cylinder Pack Puller Groups Improved

3300, 3400 And 1.7 Liter Families Of Engines

Description of Change: The cylinder pack puller groups have been improved. A new shorter base cone is used in the puller group. Also, the base plate and the bolt that fastens the plate to the cone have been eliminated. These changes allow the improved cylinder pack puller groups to be installed 25.4 mm (1.00 in) deeper into the cylinder. This increases the surface contact area with the liner and improves the tools pulling ability.

Adaptable To: The new 9U6630 Base Cone is a direct replacement for the 1U9825 Base Cone in the 8T0812, 6V9448, and 1U9593 Cylinder Pack Puller Groups for the 3300, 3400, and 1.7 Liter Families of Engines. The 1U9595 Base Plate and 307571 Bolt are not used with the new 9U6630 Base Cone.

The 1U9825 Base Cone can be modified to provide the same benefits as the new base cone. Use the procedure that follows to modify the 1U9825 Base Cone.

Illustration 1. Location of component to be removed from the cylinder puller pack groups. 9U6630 Base Cone (1). 1U9595 Base Plate (2). 307571 Bolt (3). Stud (4).

1. Remove the 307571 Bolt (3) and 1U9595 Base Plate from the bottom of the 1U9825 Base Cone (1). The bolt and base plate will NOT be reused.

2. Remove the 1U9825 Base Cone from the stud (4).

Illustration 2. Dimensions for modifying the 1U9825 Base Cone. (A) 98.22 mm (3.867 in). (B) 85.52 mm (3.367 in).

3. The length (A) of the unmodified base cone is 98.22 mm (3.867 in). Remove 12.7 mm (.50 in) of material from the base plate end of the base cone only. The length (B) of the modified base cone should be 85.52 mm (3.367 in).

4. Install the modified 1U9825 Base Cone on the stud (4).

Publication Date -01/01/1993

22. May 2018 by sam
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Installation Of Service Replacement Thrust Plates

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.

27. February 2018 by sam
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Guidelines for Proper Crankshaft Seal Handling

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

 

Introduction

Table 1
Revision Summary of Changes in SEBF9243
05 Added new serial number prefixes.
04 Updated Effectivity
Updated Introduction
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.

Summary

This guideline provides proper handling procedures for new crankshaft seals. Proper use of this guideline will prevent leaks and failures due to contamination and improper handling.

Best Practices

Background

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.

Inventory of subassembled crankshaft seals should be minimized to reduce risk of contamination and damage.

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.

Illustration 3 g02860196
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.

Illustration 4 g02860461
(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 Tooling

Always refer to the appropriate Disassembly and Assembly Manual and/or Special Instruction for the tooling needed to install crankshaft seals for an engine model.

Tooling Inspection

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.

Replacement Tooling – Replacement tooling should be in inventory and available for immediate use to reduce the risk of downtime.

Tooling Storage

Tooling storage surfaces will be clean and free from contamination.

Ensure that tooling storage conforms to the Cat dealer Contamination Control compliance Guide (PEBJ0002).

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.

Seal Inspection

Complete a visual inspection to verify the presence of the spring in crankshaft lip seals.

Note: Not all crankshaft lip seals will contain springs.

Crankshaft Inspection

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.

Assembly

Seal Lubrication

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:

https://dealer.cat.com/cda/files/2722066/
7/CaterpillarLoctiteAdhesivesSealants
ProgramFeb10.pdf

Also refer to “Doing it Right Loctite User’s Guide” for the best application of Adhesives and Sealants. This document can be downloaded at:

https://dealer.cat.com/cda/files/2722133/7/DoItRightLoctiteGuide.pdf

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.

27. February 2018 by sam
Categories: Special Instruction | Leave a comment

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