CATERPILLAR DEALER BEST PRACTICE

Cylinder Block 3500 Pitting

Salvage, Near the Upper
Liner Seal
Maintenance and Component Life Component MARC
Application
Repair Management Renewal (CRC) Management

Title: Cylinder Block 3500 Pitting Salvage, Near the

Upper Liner Seal ........................................................ 1
1.0 Introduction........................................................ 2
2.0 Best Practice Description .................................. 3
3.0 Implementation Steps ........................................ 3
4.0 Benefits ............................................................. 6
5.0 Resources Required .......................................... 6
6.0 Supporting Attachments / References ............... 7
7.0 Related Best Practices ...................................... 8
8.0 Acknowledgements ........................................... 8

DISCLAIMER: The information and potential benefits included in this document are based upon information provided by
one or more Cat® dealers, and such dealer(s) opinion of “Best Practices.” Caterpillar makes no representation or warranty
about the information contained in this document or the products referenced herein. Caterpillar welcomes additional “Best
Practice” recommendations from our dealer network.

November 2020
2011-0602-1965

Caterpillar: Confidential Yellow

 CATERPILLAR DEALER BEST PRACTICE

1.0 Introduction

Establish and define the methodology to use in Cylinder Block 3500 salvage, pitting salvage, near the
upper liner seal. This document contains information on how to salvage the pitting near the upper
liner seal using Arc spray technology.

Figure # 01 Reuse and Salvage for 3500 Engine Cylinder Blocks recommendation is observed
{0672, 0705, 0762, 1201, 1217}
Media number -SEBF8255-44

Figure # 02 typical case in Cylinder Block 3500 pitting salvage, near the upper liner seal

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2.0 Best Practice Description

These new processes have been developed in the Wagner Asia machine shop to salvage the
cylinder block 3500 on the Pitting Near the Upper Liner Seal using Arc spray technology, eliminating
the need for a sleeve and inserting its high and constant leak probability, therefore we apply the Arc
Spray technology which guarantees high adhesion, continuous operation, optimal performance under
CAT specification standards.

3.0 Implementation Steps

3.1 Pre-machined pre-machining of 1 mm-0.040” diameter and 10mm depth pitting must be
completely removed, in most cases 1mm-0.040 "diameter is sufficient

Figure # 02 Drawing of the pre-machined surface must be rough

3.3 Grit Blasting After pre-machining, all the area must be protected, to apply Grit blasting in the pre-
machine area, a roughness greater than 250µinch must be achieved.

Figure # 02 detailing protection and pre-machining

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 CATERPILLAR DEALER BEST PRACTICE

GRIT BLASTING PARAMETERS

Pressure 100 PSI
Distance 7-8”
Material Metcolite C 400
3.4 Apply Arc Spray, SM 8400 or Tafa 75B wire at a distance of 5 “with a speed of 150mm / sec, the
arc must be projected directly into the area to be recovered with a 45° angle.

Figure #03 you must apply a layer of anti-bond in the unwanted areas cover the holes with
MACHBLOC & trade.

VARIABLE OPERATION RANGE

Voltage 30V
Current 130 Amp
Pressure 60 PSI MATERIAL SULZER
Distance between REF SM8400
5” (127 mm)
gun and workpiece
DIAMETER 1/16”
Velocity 150 mm/sec
Net WT 26 lbs.
Thickness Layer 0.039"- (1 mm) Kgs. 11.79
(Measure Initial
Temperature 100-130°C

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3.5 Final Machining, is done on the EM105H Rottler machine or a similar one using the counter bore
program, cutting speed 300rpm advance 0.15mm int RT322 Rottler.

Figure #04 Se observa

VARIABLE OPERATION RANGE

Velocity 300 rpm
Flate 0.1mm
Cutting Depth 0.5mm
Program Name Cylinder Bore
Insert RT322 Rottler

Initial Evaluation Arc Spray Done Machining Finish

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4.0 Benefits

4.1 Increase the useful life of the block.

4.2 Guarantee the optimal operation without probability of leakage from the cooling system in the
area.
4.3 Eliminates the use of a sleeve top.

5.0 Resources Required

5.1 Fully integrated, self-contained coating facility with a Smart Arc Advanced Electric Wire Arc
Thermal Spray System. The leading-edge gun head is integrated to a Robot arm and a Workpiece
Manipulator (Turntable). The system produces highly reliable electric wire arc spray coatings for wear
protection, restoration of component dimension and corrosion protection

5.2 CNC Engine Block Axis Boring, Surfacing & Line Boring machine: Automatic Tool Changer,
Block Surfacing, Blue Print Boring, Boring & Sleeving, Circular Interpolation, Connecting Rod
Boring, Cylinder Boring, Cylinder Head Resurfacing, Lifter Boring, Line Boring, Multi Purpose
CNC (Custom Parts), Thrust Cutting.

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5.3 Grit blasting equipment, applied for cleaning and anchoring pattern before metallization.

6.0 Supporting Attachments / References

6.1 Reuse and Salvage for 3500 Engine Cylinder Blocks recommendation is observed Media number
-SEBF8255-44
6.2 Reuse And Salvage Guidelines Fundamentals of Arc Spray for Reconditioning Components
Media Number -SEBF9238-13

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7.0 Related Best Practices

7.1 HS RV II Silicone Engine Block Galley Covers Used For Protection During Top Deck Arc Spray
Salvage.
7.2 Tooling for Deburring Cylinder Block Top Deck after Machining.
7.3 Reconditioning of Cylinder Block – Cleaning of Metal Spray Waste.

8.0 Acknowledgements

This Best Practice was written by:

Name: Mario Lucena / Machine Shop Supervisor
E-mail: [email protected]
Company: Wagner Asia Equipment

Recognition:
Direction:
Luis Jimenez/Product Support Shops Director
Team:
Pablo Salazar / Machine Shop Manager
Mauricio Guiza/ CRC Manager
Yair Teheran /CRC Supervisor OJT

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