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SEBF8068 гильзы
SEBF8068 гильзы
Cylinder Liners
SEBF80680001
Cylinder Liners
SMCS - 1201; 1213
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SEBF8068-01
July 2001
SMCS Codes: 1201 1213
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE
OPERATIONS
Cylinder Liners
Summary of Revisions
Page Description
Introduction
This guideline enables dealers and their customers to benefit from cost reductions
made possible through an established parts reusability and salvage program. Every
effort has been made to provide the most current and relevant information known to
Caterpillar Inc. Since the Company makes ongoing changes and improvements to its
products, this guideline must be used with the latest technical information available from
Caterpillar to ensure such changes and improvements are incorporated where
applicable.
Many times, the installation of new cylinder liners is not necessary during an engine
overhaul. Instead, the installation of used cylinder liners can result in a large decrease
in the cost of the overhaul. To see if and how cylinder liners can be used again, make a
comparison between the parts you remove from the engine and the illustrations and
measurements shown in this book. Follow salvage (reconditioning) recommendations
carefully and completely. Never use a cylinder liner again if the recommendation in this
book is not to use it again. Also, during salvage operations, correct any conditions that
caused the original failure or wear.
Nomenclature
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Illustration 1
Visual Inspection
Before you start the visual inspection, remove any rust and/or deposits from the outside
surface of the liner. Use glass beads, a wire brush installed on a pedestal grinder or a
similar method which will not damage the inside diameter or the top or bottom of the
flange. See Illustration 2.
Outside Surface
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Illustration 2
Rust and deposits, like these, on the outside surface must be removed before the visual inspection.
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Illustration 3
Use again -
if the chip is not extended across the complete area and any burrs or sharp edges are removed with a file.
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Illustration 4
Light erosion (gradual wear of material) in the top groove only (shown as A).
Use again -
unless the outside of the liner has pits or erosion that goes into either of the lower two seal grooves (shown as B).
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Illustration 5
Crack.
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Illustration 6
Small pits like these are acceptable only if they are limited to one or two sides and the liner is installed with the pits toward the front and/or
rear of the engine (not the thrust side).
Use again -
unless there are pits on more than two sides.
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Illustration 7
Deep pits.
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Illustration 8
Deep pits.
If the liner has pits between the seal grooves and the filler band groove and they are
deeper than 2.3 mm (0.090 inch), do not use the liner again. See Illustration 9. To check
the depth of a pit, grind an 8S-2251 Drill as shown in Illustration 10. If the drill goes into
a pit up to lip L in Illustration 10, the pit is too deep.
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Illustration 9
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Illustration 10
Flange Area
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Illustration 11
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Do not use again
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Use again
Illustration 12
Pits and fretting under the liner flange. Large pits or groups of pits are not acceptable, especially in the radius. Fretting (shown in the bottom)
is acceptable when it is circumferential and does not prevent the liner from sealing. Measure flange thickness.
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Illustration 13
Small Pits.
Use again
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Illustration 14
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Illustration 15
Use again -
only if the damage is not extended completely across the fire dam and any burrs or sharp edges
are removed.
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Illustration 16
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Illustration 17
Use again -
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Illustration 18
Flange Thickness
Measure the thickness of the flange with a
6V-7059 Micrometer (Illustration 19). Use the liner again only if it is acceptable according to the
specifications in Chart A.
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Illustration 19
Chart A
4.50 inch D330, D333, 1673 10.261 mm (0.4040 inch) 10.241 mm (0.4032 inch)
4.75 inch D330C, D333C, 3304,3306, 1673C, 10.282 mm (0.4048 inch) 10.262 mm (0.4040 inch)
D334,1674
5.4 inch D343, 1693, D346, D348, D349 13.360 mm (0.5260 inch) 13.340 mm (0.5252 inch)
5.4 inch 3400 Series Engines 8.890 mm (0.3500 inch) 8.870 mm (0.3492 inch)
6.25 inch D353, D379, D398, D399 12.827 mm (0.5050 inch) 12.807 mm (0.5042 inch)
170 mm 3500 Series Engines 12.650 mm (0.4980 inch) 12.630 mm (0.4972 inch)
Note: Liner projection (the amount the liner is extended above the block or
space plate, according to the engine design) must also be measured at
assembly. Use the specifications and instructions given in the service
manual. If liner projection is less than 0.051 mm (0.002 inch),
do not use the liner again unless shims are installed. Refer to the correct service
manual and Special Instruction, FM055228-03 for more information on the addition of
shims.
Inside Surface
Use a fluorescent light and an FT1711 Light Table (Illustration 20) to inspect for scratches and
pits on the inside surface of the liner (Illustration 21). A fluorescent light works much better than
incandescent (filament) bulbs.
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Illustration 20
Complete drawings for the FT1711 Light Table are available from Division Service Managers.
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Illustration 21
Note: If pits or light rust spots on the inside surface are directly opposite
pits on the outside surface, do not use the liner again because the pits can
go into the bore.
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Illustration 22
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Illustration 23
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Illustration 24
Note: Use a FLEX-HONE brush to remove light rust or shiny areas on the inside
surface. Liners can be used again if ALL rust, pits and shiny areas are removed
with a FLEX-HONE brush or by the hard hone procedure.
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Illustration 25
Use again -
only if, after use of a FLEX-HONE or hard hone, the spots can not be seen or felt.
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Illustration 26
Use again -
only if, after use of a FLEX-HONE or after the hard hone procedure, all shiny areas are removed and there is a good crosshatch pattern over
the complete surface. Refer to Illustration 32.
NOTICE
If shiny areas have completely worn away a section of the original crosshatch
pattern, do not use a FLEX-HONE. Use only the hard hone procedure on badly
worn liners.
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Illustration 27
Use again -
only if, after use of a FLEX-HONE, the water rings / spots can not be seen or felt with a fingernail.
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Illustration 28
Use again -
only if, after the hard hone procedure, the diameter is acceptable when measured with a dial bore gauge and the step is completely
removed.
1P-3537 Dial Bore Gauge Group-English units (bore gauge and setting fixture). Refer to
Special Instruction, GMG00981.
or
6V-7898 Dial Bore Gauge-Metric units-with the 6V-7899 Setting Fixture-Metric units.
Refer to Special Instructions, SMHS8253 and SMHS8254.
Measure the bore in the cylinder liner at two points, 90 apart at the upper end of the
surface, at the point of maximum wear. Make another check at the lower end of the
liner, at the lowest point that the rings wear. See Illustration 30.
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Illustration 29
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Illustration 30
If all bore measurements are acceptable according to Column 2 in Chart B, the liner can
be used again with the original piston, a reconditioned piston or a new piston. If there is
an easily seen wear step, and the FLEX-HONE Brush does not remove it, use the hard
hone procedure.
If the upper bore measurements are acceptable according to Column 3 in Chart B (but not
Column 2), the liner can be used again with the original piston ONLY. If not, the wear step in
the liner can break a ring. IF THE WEAR STEP IS REMOVED WITH THE HARD HONE
PROCEDURE, the liner can be used again with any piston, but the upper bore measurements
must be acceptable according to Column 3 in Chart B. The middle of the liner and bottom bore
measurements must still be acceptable according to Column 2.
DIAMETER SPECIFICATIONS FOR CYLINDER LINERS
Column 1 Column 2 Column 3
D330, D333, 1673, D336 (4.50 114.325 0.025 mm 114.300 - .114.427 mm 114.300 - .114.529 mm
inch) (4.501 0.001 inch) (4.500 4.505 inch) (4.500 - 4.509 inch)
D343, 1693, D346, D348, D349, 137.185 0.025 mm 137.160 - 137.287 mm 137.160 - 137.389 mm
90 V8, 3406, 3408, 3412, (5.4 (5.401 0.001 inch) (5.400 - 5.405 inch) (5.400 - 5.409 inch)
inch)
D353, D379, D398, D399, (6.25 158.775 0.025 mm 158.750 - 158.903 mm 158.750 - 158.979 mm
inch) (6.251 0.001 inch) (6.250 - 6.256 inch) (6.250 - 6.259 inch)
Note: Dimensions in Chart B are for natural gas engines also. Column 3
dimensions are for the area at and above the upper end of the surface at
the point of maximum wear. Use Column 2 dimension for the remainder of the
liner
NOTICE
Procedures to Hone
Some cylinder liners can be used again after the use of a FLEX-HONE; normally, these
liners have very little, if any, damage and basically only need a new crosshatch pattern.
Other liners have heavier damage which must be removed by a procedure to hard
hone. There are also, at timers, liners which are still shiny after use of a FLEX-HONE;
the only way to use liners like these again is to hard hone them.
FLEX-HONE Procedure
A FLEX-HONE is a flexible nylon brush with an abrasive (rough) material on the brush tips.
Before a used cylinder liner can be installed in an engine, it must have a good crosshatch pattern
(Illustrations 31 and 32). This crosshatch pattern must be over the complete inside surface of the
cylinder liner in the ring contact area. No shiny areas are permitted in this section of the liner. A
good crosshatch pattern and a surface finish of 0.38 - 0.76 micrometers (15 - 30 microinches) are
needed on the inside surface of all used cylinder liners installed in Caterpillar engines.
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Illustration 31
Crosshatch pattern
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Illustration 32
Crosshatch pattern. All liners must look like this, with no pits, rust, scratches or shiny areas in the ring contact area.
1. Use a FLEX-HONE with 180 grit abrasive (measurement of the abrasive) on the
tips.
NOTE: These specifications are for cylinder liners ONLY. See the Tool Guide for
information on FLEX-HONES for engines without liners.
2. Do not use the FLEX-HONE dry. Use kerosene or a light solvent for lubrication of
the FLEX-HONE and the cylinder liner. Do not use lubricating oil with the FLEX-
HONE on Caterpillar cylinder liners.
3. Turn the FLEX-HONE between 350 and 500 rpm. A 13 mm ( 1/2 inch) electric drill
will turn the FLEX-HONE best.
4. While the FLEX-HONE turns, move it up and down the liner at a rate of
approximately 30 strokes per minute
(1 second up and 1 second down). This rate can be changed, if necessary, to
give the correct angle (130 10 ) crosshatch pattern. A crosshatch pattern of
this angle gives the best mixture of wear resistance and oil control. If the slope of
the crosshatch pattern is much less than 130 , decrease the number of strokes
per minute or increase the rpm of the drill. If the slope of the crosshatch pattern is
too flat (much more than 130 ), increase the number of strokes per minute or
decrease the speed of the drill.
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5. Illustration 33
6. FLEX-HONE brush.
7.
8. If the FLEX-HONE is not worn, use it for approximately 30 seconds. If possible
use a new FLEX-HONE. Worn FLEX-HONES will not cut deep enough and the
surface can still be shiny or too smooth.
9. Use a new liner as a reference for the correct crosshatch pattern.
10. See "Procedure to Clean Liners" for information on protection of liners from rust
and preparation for their storage.
While cylinder liners can be salvaged with a FLEX-HONE in practically any type
of fixture that will hold the liner and solvent, the FT1528 Liner Honing Machine
and two FT1524 Tub Assemblies can increase the efficiency and speed of the
procedure. See Illustration 34.
Two FT1524 Tub Assemblies and six cylinder liner plates (Illustration 35) are
also needed.
Note: Use of the liner honing machine and tub assemblies is limited to 4.5 inch, 4.75
inch, 5.4 inch, 5.75 inch, 6.25 inch and 170 mm diameter liners.
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Illustration 34
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Illustration 35
Four liners installed on a cylinder liner plate.
1. Put the correct cylinder liner plate in one of the tubs and install the liners in the
plate.
2. Fill the tub with enough kerosene, diesel fuel or light solvent to keep the bottom
76.2 mm (3 inch) of the liners under the solvent.
3. Push the tub in position and hone the liners for 30 - 60 seconds.
4. Remove the tub from the liner machine and lift the liner plate from the tub with
the liners in place.
5. Put the liner plate (with the liners) in the second tub, which is fitted with water
and detergent. The bottom 76.2 mm (3 inch) of the liners must be under the
water and detergent solution.
6. Remove FLEX-HONE Brushes and install nylon brushes.
7. Push the second tub into the machine and clean the liners with the nylon brushes
for
1 - 2 minutes or until all debris is completely removed.
Note: Drawings for the FT1528 Liner Honing Machine and FT1254 Tub
Assembly are available from Division Service Managers. The machine can also
be ordered as an already fabricated unit, complete with liner tubs and plates
from:
Rust Tractor Company
4000 Osuna Road, N.E.
Albuquerque, N.M. 87109
U.S.A.
Telephone: (505) 345-8411
8.
9. Use new solvent and detergent and water solution every 100 liners.
Before the procedure to hone, wash the liners in solvent to remove all carbon and oil.
Make sure each liner is completely dry before it is installed in the honing fixture. Use a
clean, dry cloth. Also, take several measurements to see how round the bore is. Take
the same measurements after the liner is installed in the fixture. The purpose of these
measurements is to be there has been no distortion of the liner during installation. If
there is an indication of distortion, loosen the clamp and carefully tighten it again.
New stones must be "seated" to the liner bore. To do this, use an old liner and run the
hone up and down the bore two or three times. The corners of the stones will wear
away more rapidly as the stones take the shape of the curve of the bore. Remove the
old liner and put the liner to be honed in position. Approximately 20 liners can be honed
with a set of stones, unless the stones become damaged or "loaded." This condition
results from debris embedded (become a part of) in the surface of the stone. If the stone
becomes loaded, use a Sunnen MAN-700 Diamond Dresser or similar abrasive stick to
remove the debris. Streaks in the crosshatch pattern, as shown in Illustration 36, can be
an indication of a bad, worn or loaded stone.
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Illustration 36
To find the most acceptable rpm at which to hone, divide 1,200 by the hole diameter in
inches or divide 30,500 by the hole diameter in millimeters. For example, for a 5.4 inch
liner:
or
Use a "roughing" stone (70 grit), to hone the area above and including the wear ridge.
This is known as coarse honing. At first, hone in short strokes, to remove the ridge, but
do not hone too long in one area or the stone will cut a new ridge. See Illustration 37.
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Illustration 37
Do not hone any longer than necessary on any one wear ridge or the stone will cut a new one as shown here.
Stop the hone every 5 - 10 seconds and increase the pressure of the stones against the
cylinder liner bore.
After coarse honing, use a 600 grit stone for 30 to 45 seconds. This will give the correct
surface finish and change the bore size by only a small amount. This is known as "finish
honing." Honing oil MUST be used during this operation. Also, check the bore size,
crosshatch pattern and inspect for any shiny areas.
Remove only enough material to remove any wear steps, pits, grooves and rust. Chart
B on page 12 gives three specifications for cylinder bores
Column 2 gives specifications for the area below the wear ridge in the liner bore.
Column 3 gives specifications for the area above and including the wear ridge only.
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Illustration 38
It is important to follow the specifications given in Chart B exactly. For example, if the
lower area of the liner bore is honed to a specification larger than that given in Column
2, erosion of the block and liner in the water jacket area or cracks in piston skirts can
result. Since the maximum acceptable specifications above and below the wear ridge
are different, bore taper is acceptable as long as the specifications shown in Chart B are
kept. See Illustration 39.
The chart that follows gives the Sunnen part numbers (and Caterpillar part numbers,
where available, in parentheses) of the tools and stones necessary for the procedure to
hard hone. Use only these tools and stones.
Rough Finishing
Bore Stone Stone Honing Quick
Size (70 grit) (600 grit) Tool Coupler
* For use only with automatic adjusting hone for Sunnen CK-10 machine.
Note: For engines without liners, see the Service Manual for
recommendations.
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Illustration 39
A small amount of bore taper is acceptable. Make sure there is no more than 0.001 inch taper on the diameter per 1 inch of the bore.
With some modification to its original design, the FT-1528 Liner Honing Machine
(Illustration 34) can be used in the hard hone procedure. Specifically: four existing W.
W. Grainger 3X774 Pulleys must be removed and four
W. W. Grainger 3X844 Pulleys installed in their place and both existing W. W. Grainger
4L-350 Belts installed instead. This modification will decrease spindle speed from about
360 rpm to about 240 rpm and increase honing torque. The new parts are available
directly from:
W. W. Grainger
5959 W. Howard St.
Dept. TR
Chicago, IL 60648
U.S.A.
Telephone (312) 647-8900
Telex: 910-223-3651
Some modification to the FT1524 Tub Assembly is also necessary. The tub and holding
plate must be fastened to the frame of the machine to keep the unit stationary. Use a
bracket fastened to both sides of the machine frame. Install the Sunnen AN-815 Hone
(with the stones) in one of the four spindles. Put the liner in the tub and tighten the
clamp.
Note: Too much stone pressure will cause the honing motor to stall an/or
cause the belts to slide.
During the procedure to hone, stop the machine, as necessary, to increase the pressure
on the stones. Most stones will remove approximately 0.10 mm (0.004 inch) of material
per minute, so take measurements of the bore from time to time.
The FT1528 Liner Honing Machine can also be used to clean the liners after the
procedure to hone.
Other Fixtures
Note: The CK-10 uses a 152 mm (6.0 inch) long stone; the stones for the
CK-10 given in the chart under the section "Tool and Stone
Specifications," are acceptable for all Caterpillar liners, of all diameters.
For 6.25 inch cylinder liners, the FT1371 Honing Fixture can be used. Refer to Special
Instruction, SEHS7220.
The FT1688 Holding Fixture, originally fabricated to hone track idler and roller bearings,
can also be used to hone cylinder liners after some modification. The basic design of
the fixture gives the necessary support and oil delivery system. Put four pieces of wood
in the holding cradle, as shown in Illustration 40. This modification will give the
necessary support but not damage the liner. Fasten the liner to the fixture with chains or
straps; be careful of distortion to the liner (Illustration 41).
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Illustration 40
Illustration 41
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Illustration 42
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Illustration 43
After it has been thoroughly washed, make sure the liner is completely dry. Use a clean
white paper towel or cloth. This way any debris still on the liner will show on the paper
towel or cloth. See Illustration 44.
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Illustration 44
Use a white cloth to see if the liner is clean. A gray color is an indication that dirt or debris is still present.
Put a layer of engine oil or other rust preventive over the clean, dry liner immediately.
Without protection, a clean, correctly honed liner can show rust in minutes.
Copyright 1993, 2004 Caterpillar Inc. Fri Oct 29 18:18:07 UTC+0400 2004
All Rights Reserved.
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