C-10 and C-12 Truck Engines Caterpillar

Piston Rings

The pistons of the engine have a keystone design ring groove. The piston rings are a keystone ring. The 1U-6431 Piston Ring Groove Gauge is available to check the top ring groove in the piston. Use the 8T-3149 Plug Gauge that is part of this Gauge Group to check the top ring groove on the piston. Refer to the instruction card for correct use of the 1U-6431 Piston Ring Groove Gauge .

Connecting Rods and Pistons

The C-10 engine uses a 1U-9593 Cylinder Pack Puller with a 1U-9897 Bridge , and a 1U-6319 Socket to remove a cylinder pack (connecting rod and piston) from the block. Use either the 1U-9788 Nylon Brush for reconditioning the cylinder liners. Use the 1U-9787 Flexible Hone for reconditioning the cylinder liners.

Use the 4C-3601 Piston Ring Expander in order to remove the piston rings. Use the 4C-3601 Piston Ring Expander in order to install the piston rings.

Use the 1U-6684 Piston Ring Compressor in order to install the pistons into the cylinder block.

Tighten the connecting rod nuts in the step sequence that follows:

1. Put 4C-5593 Anti-Seize Compound Thread Lubricant on bolt threads and contact surfaces of nut and cap.

2. Install the connecting rod nuts according to the following procedure:

   Tighten the connecting rod nuts to the following torque: ... 130 ± 7 N·m (95 ± 5 lb ft)

3. Put a mark on each nut and end of bolt.

4. Tighten each nut by the following method:

   Tighten the nut: ... 60 ± 5 degrees

The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are worn, check the bore size. This can be an indication of wear because of a loose fit.

Connecting Rod and Main Bearings

Connecting Rod Bearings

Connecting rod bearings are available with 0.508 mm (.0200 inch) and 0.762 mm (.0300 inch) smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been ground.

Main Bearings

Main bearings are available with 0.508 mm (.0200 inch) and a 0.762 mm (.0300 inch) smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been ground.

Main bearings are also available with a larger outside diameter than the original size bearings. These bearings are used for the cylinder blocks with the main bearing bore that is made larger than the bore's original size. The size that is available has a 0.508 mm (.0200 inch) outside diameter that is larger than the original size bearings.

The Special Instruction, SMHS7606 gives the instructions for the use of 1P-4000 Line Boring Tool Group . The 1P-4000 Line Boring Tool Group is used in order to check the alignment of the main bearing bores. The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bore. The Special Instruction, GMGO0981 gives the instructions for the use of 1P-3537 Dial Bore Gauge Group .

Cylinder Block

Illustration 1	g00285686
1P-3537 Dial Bore Gauge Group

If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications, "Cylinder Block". Alignment error in the bores must not be more than 0.08 mm (.003 inch).

The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.

Cylinder Liner Projection

1. Clean the cylinder liner flange and the cylinder block surface. Remove any nicks on the top of the cylinder block.
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   Table 3

   Needed Components
   Item	Part Number	Description	Quantity for One Cylinder	Quantity for Six Cylinders
   1	8T-4193	Bolt	6	36
   2	2S-5658	Washer	6	36
   3	8F-1484	Washer	6	36
   4	7K-1997	Washer	6	36

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Illustration 2	g00441535
Location of the Components (1) Bolt (2) Washer (3) Washer (4) Washer

2. The illustration and the chart identify the components that are required. An 8T-0455 Liner Projection Tool Group is also required.

3. The components should be assembled in the order that is shown in 2. The 7K-1977 Washer (4) is made of a cotton fabric that is impregnated with resin. The washer will not damage the sealing surface of the cylinder block.

   Note: Inspect the washer before measuring the liner projection. Replace the washer if the washer is worn or damaged.

4. Tighten bolts (1) evenly according to the following procedure:

   First tighten each bolt to the following torque. ... 27 N·m (20 lb ft)

   Then tighten each bolt to the following torque. ... 54 N·m (40 lb ft)

   Then tighten each bolt to the following torque. ... 68 N·m (50 lb ft)

   Again tighten each bolt to the following torque. ... 68 N·m (50 lb ft)

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Illustration 3	g00441537
(5) Bolt (6) Dial indicator (7) Gauge body (8) Gauge

5. Loosen bolt (5) until dial indicator (6) can be moved. Place gauge body (7) and dial indicator (6) on the long side of gauge.

6. Slide the dial indicator (6) into the position when the point contacts the gauge (8) . Slide the dial indicator until the needle of the gauge makes a quarter of a revolution clockwise. The needle should be in a vertical position. Tighten bolt (5) and zero indicator.

7. Put the gauge body (7) on the plate for the cylinder block. The indicator point should be on the liner flange. Read the dial indicator in order to find the amount of liner projection. Check the projection at four locations (every 90 degrees) around each cylinder liner.
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   Table 4

   Specifications
   Liner Projection	0.040 to .200 mm (.0016 to .0079 inch)
   Maximum Variation in Each Liner	0.050 mm (.0020 inch)
   Maximum Average Variation Between Adjacent Liners	0.050 mm (.0020 inch)
   Maximum Variation Between Liners	0.100 mm (.0040 inch)

8. If a liner does not meet the recommended cylinder liner projection specification, check the following parts:
   • The depth of the cylinder block bore should be 100.00 ± 0.03 mm (3.937 ± .001 inch) .

   • The liner flange should be 100.12 ± 0.03 mm (3.942 ± 0.001 inch) .

   If the depth of the cylinder block bore is out of specification, replace the cylinder block. Then repeat the liner projection measurements. If the liner flange is out of specification, replace the liner. Then repeat the liner projection measurements.

Flywheel and Flywheel Housing

Face Runout (Axial Eccentricity) of the Flywheel Housing

Illustration 4	g00285931
8T-5096 Dial Indicator Group

If you use any other method except the method that is given here, always remember that the bearing clearance must be removed in order to receive the correct measurements.

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel housing.

2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

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Illustration 5	g00285932
Checking Face Runout Of The Flywheel Housing

3. Turn the flywheel while the dial indicator is set at 0.0 mm (.00 inch) at location (A) . Read the dial indicator at locations (B) , (C) and (D) .

4. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.38 mm (.015 inch), which is the maximum permissible face runout (axial eccentricity) of the flywheel housing.

Bore Runout (Radial Eccentricity) of the Flywheel Housing

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Illustration 6	g00285934
8T-5096 Dial Indicator

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the flywheel housing.

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Illustration 7	g00285932
Checking Bore Runout Of The Flywheel Housing

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Illustration 8	g00285936

2. While the dial indicator is in the position at location (C) adjust the dial indicator to 0.0 mm (.00 inch). Push the crankshaft upward against the top of the bearing. Refer to Illustration 8. Write the measurement for bearing clearance on line 1 in column (C) .

   Note: Write the measurements for the dial indicator with the correct notations. This notation is necessary for making the calculations in the chart correctly.

3. Divide the measurement from Step 2 by two. Write this number on line 1 in columns (B) and (D) .

4. Turn the flywheel in order to put the dial indicator at (A) . Adjust the dial indicator to 0.0 mm (.00 inch) .

5. Turn the flywheel counterclockwise in order to put the dial indicator at (B) . Write the measurements in the chart.

6. Turn the flywheel counterclockwise in order to put the dial indicator at (C) . Write the measurement in the chart.

7. Turn the flywheel counterclockwise in order to put the dial indicator at (D) . Write the measurement in the chart.

8. Add the lines together in each column.

9. Subtract the smaller number from the larger number in column B and column D. Place this number on line III. The result is the horizontal eccentricity (out of round). Line III in column C is the vertical eccentricity.

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Illustration 9	g00286046
Graph For Total Eccentricity (1) Total vertical eccentricity (2) Total horizontal eccentricity (3) Acceptable value (4) Unacceptable value

10. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

11. If the point of the intersection is in the "Acceptable" range, the bore is in alignment. If the point of intersection is in the "Not acceptable" range, the flywheel housing must be changed.

Face Runout (axial eccentricity) of the Flywheel

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Illustration 10	g00286049
Checking Face Runout Of The Flywheel

1. Refer to Illustration 10 and install the dial indicator. Always put a force on the crankshaft in the same direction before the dial indicator is read. This will remove any crankshaft end clearance.

2. Set the dial indicator to read 0.0 mm (.00 inch) .

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.15 mm (.006 inch), which is the maximum permissible face runout (axial eccentricity) of the flywheel.

Bore Runout (radial eccentricity) of the Flywheel

Illustration 11	g00286054
Checking Bore Runout Of The Flywheel (1) 7H-1945 Holding Rod (2) 7H-1645 Holding Rod (3) 7H-1942 Dial Indicator (4) 7H-1940 Universal Attachment

1. Install the 7H-1942 Dial Indicator (3) . Make an adjustment of the 7H-1940 Universal Attachment (4) so that the dial indicator makes contact on the flywheel.

2. Set the dial indicator to read 0.0 mm (.00 inch) .

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.15 mm (.006 inch), which is the maximum permissible face runout (radial eccentricity) of the flywheel.

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Illustration 12	g00286058
Flywheel Clutch Pilot Bearing Bore

5. To find the runout (eccentricity) of the pilot bearing bore, use the preceding procedure.

6. The runout (eccentricity) of the bore for the pilot bearing in the flywheel must not exceed 0.13 mm (.005 inch) .

Vibration Damper

Illustration 13	g00398558
Vibration Damper and Pulley (1) Damper assembly (2) Pulley (3) Crankshaft (4) Bolt (5) Bolt

The vibration damper is installed on the front of crankshaft (3) . The vibration damper (1) has a weight in a case. The space between the weight and the case is filled with viscous fluid. The weight moves in the case in order to limit the torsional vibration.

Replace the damper if any of the following conditions exist:

• leaking

• bent

• damaged

• worn bolt holes with loose fit for bolts

• crankshaft failure due to torsional forces

Note: Bolts (4) must be tightened to a torque of 240 ± 40 N·m (175 ± 30 lb ft) .

Note: Bolts (5) must be tightened to a torque of 55 ± 10 N·m (41 ± 7 lb ft) .