3145, 3150 & 3160 INDUSTRIAL ENGINES Caterpillar


Basic Block

Usage:

Cylinder Block Honing

The following preliminary check is essential to determine if honing is necessary, and if so, the size to hone.

Measure all cylinder bores during disassembly using the 1P3537 Bore Gauging Group. This group includes a 1P3535 Dial Bore Gauge Group and a 1P3536 Size Setting Fixture Group. The bore gauging group provides more accurate measurements than other methods, such as inside micrometers. When setting the gauge, always be sure the gauge pin has sufficient travel to measure the points of maximum wear in the bore. In a cylinder bore, maximum wear is usually across the diameter perpendicular to the crankshaft centerline, either at the top or bottom of ring travel. Normal wear usually will not exceed .020 in. (0.51 mm); however, if bore wear is greater than .020 in. (0.51 mm), hone the block .040 in. (1.02 mm) oversize. The fact that the block can be honed both .020 in. (0.51 mm) and .040 in. (1.02 mm) oversize will allow a block to be reconditioned twice under normal wear conditions. The standard bore size is 4.5000 to 4.5015 in. (114.300 to 114.338 mm).


1P3537 BORE GAUGING GROUP

When reconditioning an engine, the bore size is the determining factor as to the necessity of honing the bores. If bores are worn .006 in. (0.15 mm) more than the standard size, the block should be honed. However, additional service may be obtained without honing if wear does not exceed the maximum wear limit of .0085 in. (0.216 mm).

Before honing, inspect the bottom of each cylinder bore adjacent to the main bearing saddle or web. Some of the saddles may overlap the edge of cylinder bores enough to interfere with honing. Where overlap exists, machine a relief in the saddle to provide clearance for the honing tool. The radius of the relief must be concentric with the cylinder bore and .030 ± .005 in. (0.76 ± 0.13 mm) larger than the bore radius. The relief extends .62 in. (15.7 mm) beyond the bottom of the bore, as shown. This provides adequate clearance for honing.


RELIEF IN SADDLES and CHAMFER AFTER HONING

When honing, check bore size at several locations in the length of the bore and around the circumference. Specifically measure at points perpendicular to the crankshaft centerline at locations .25 in. (6.4 mm) from each end and at center of bore. These three specific locations are primary gauge points during and after honing.


PRIMARY GAUGING POINTS

When honing cylinder blocks, maintain the specified dimensional surface finish and crosshatch tolerances to obtain satisfactory oil control. The tolerances specified are virtually the same as those used for original bore finish at the factory, and can be obtained with an automatic honing machine such as the Sunnen CK-10. This machine has been evaluated and found to give satisfactory results.

The Sunnen CK-10 machine is available from Sunnen Products Company, 7910 Manchester Avenue, St. Louis, Missouri, 63143.

Due to the cost of suitable honing equipment, it may be more expedient to have the honing done by a shop equipped with a Sunnen CK-10 or equivalent. A list of these shops appears at the back of this manual.

Transit Preparation

The following Steps can prevent damage to the block in transit to a shop.

1. Completely disassemble, but do not clean block. The residual oil on the surface will prevent rust.

2. Enclose the block in an industrial plastic bag and position it with the oil pan surface on a suitable wood pallet or equivalent. Dimensions of a suitable wood pallet are shown.


TRANSPORTING PALLET

3. Cover the block with 1/2 in. (12.7 mm) thick plywood or equivalent, and band block to the pallet.

4. Follow similar instructions when block is returned. To prevent rust, the block should not be cleaned after honing, the film of honing oil provides ample protection from rusting.

NOTE: If blocks are to be stored for any length of time, clean and anti-rust after honing.

Cleaning Procedure

After honing is completed, and before assembling the engine, the cylinder block must be cleaned and prepared according to the following instructions.

1. If not previously removed, the camshaft bearings must be removed to permit thorough cleaning of the oil passages. To remove the bearings, see the topic CAMSHAFT BEARINGS REMOVAL AND INSTALLATION.

2. Using the 1P3565 Chamfering Group, remove the sharp corner at the bottom of the cylinder bores as shown. This is essential to prevent scuffing the piston skirts. The chamfer should be approximately 10° x .09 in. (10° x 2.3 mm).


CHAMFERING BORE


NOTICE

Avoid damage to the cylinder bore surface or any other parts.


3. Using the 1P5580 Brush Group and a strong detergent and water solution, clean the following areas of the block.

A. Main oil gallery and supply passage. Use the 1P5572 or 1P5573 Brush and stroke several times while rotating the brush.

B. Camshaft bearing oil passages. Use the 1P5571 Brush and stroke several times while rotating the brush.

C. Cylinder bores. Use the 1P5574 Brush and stroke each bore for one minute while rotating the brush at 1000 rpm.


NOTICE

Incomplete cleaning will result in piston seizure or rapid wear of cylinder bores, pistons and rings. Only thorough rotary brushing with a strong detergent and water solution satisfactorily removes abrasive particles.



1P5580 BRUSH GROUP

4. Thoroughly clean the cylinder block in an agitator-type cleaning tank. This type of cleaning should follow the brushing of the cylinder bores but is not sufficient by itself for cleaning.

5. Coat all machined surfaces immediately after cleaning with engine oil (SAE 30). Keep the block covered to exclude dirt until assembled.

Sunnen CK-10 Machining Data

Main Bearing Bores

With main bearing caps installed and tightened to the torque given in the chart TIGHTENING PROCEDURE FOR THE BOLTS FOR MAIN BEARING CAPS. Check main bearing bore size using the 1P3537 Gauging Group. If the main bearing bore is not within 3.7075 ± .0015 in. (94.171 ± 0.038 mm), replace the main bearing cap. It is necessary to line bore the replacement service caps. See the topic LINE BORING MAIN BEARING CAP.

When installing main bearing caps on a reconditioned engine, use new main bearing cap bolts and washers.

Main Bearing Cap Guide Width

Check the width of the main bearing cap guide. The guide width of a new cap is 6.5600 ± .0007 in. (116.624 ± 0.018 mm). Replace main bearing caps that are less than the minimum width of 6.5580 in. (116.573 mm). It is necessary to line bore the replacement service caps. See the topic LINE BORING MAIN BEARING CAP.

When installing main bearing caps on a reconditioned engine, use new main bearing cap bolts and washers.

Line Boring Main Bearing Cap

When reconditioning a block, and one main bearing cap is replaced, line bore the replaced cap. If it is necessary to replace more than one cap, it is recommended that all of the main bearing bores be line bored. See the topic LINE BORING MAIN BEARING BORES.

Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.


CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.

Place 1P2344 Centering Rings (1), with oiler (2) up, on each side of the cap being replaced. For an end cap, place 1P2344 Centering Rings (1) in the second and fourth main bearing bores.

Mark new cap to correspond with number on saddle and install the new unbored cap (5). Mark cap and saddle "OS" for oversize next to location number. Tighten the unbored cap bolts (4) to the torque shown in the chart TIGHTENING PROCEDURE FOR THE BOLTS FOR MAIN BEARING CAPS. Place the original bearing caps (3) over the centering rings (1). Tighten the original bearing cap bolts (6) hand tight.


CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Original bearing caps. 4. Bolts (two). 5. Unbored cap. 6. Bolts (four).

Oil boring bar (7) and insert it through centering rings (1). Tighten bolts (6) to a minimum of 20 lb. ft. (25 N·m) and a maximum of 50 lb. ft. (70 N·m) while spinning boring bar (7) to check for binding. Centering rings (1) must be seated in bearing saddles after tightening.


INSTALLING BORING BAR
6. Bolts (four). 7. 1P2352 Boring Bar.

Bolt torsion bar assembly (8) loosely to opposite end of block from which boring bar will be driven. Install feed assembly (10) into boring bar and tighten setscrew (9). Slide feed assembly (10) onto torsion bar assembly (8) and tighten bolt (11). Tighten bolt (12) finger tight. Boring bar must slide in and out freely after these tightening operations. Tighten thumbscrew (13).


FEED ASSEMBLY INSTALLED
8. 1P2369 Torsion Bar Assembly. 9. Setscrew. 10. 1P2365 Feed Assembly. 11. Bolt. 12. Bolt. 13. Thumbscrew.

To set tool in tool holder. Set micrometer (15) to 3.7075 in. (94.171 mm). Place centering ring (1) on 1P2370 Micrometer Bracket Assembly. Move micrometer (15) until spindle (14) contacts centering ring (1). Tighten bolt (16). Back of micrometer thimble and recheck micrometer setting. Repeat above steps until micrometer setting is accurate.


SETTING MICROMETER
1. 1P2344 Centering Ring. 14. Micrometer spindle. 15. Micrometer. 16. Bolt.

Place tool holder (17) on the 1P2370 Micrometer Bracket Assembly. Align mark on tool holder (17) with hole in shaft (18). Place tool bit (20) in tool holder (17) and set the micrometer .070 in. (1.78 mm) less than the finish bore diameter of 3.7175 ± .0005 in. (94.425 ± 0.013 mm). Turn the bracket assembly arm until micrometer spindle aligns with tool bit (20). Adjust tool bit (20) by pushing it with the 9S8521 Rod (19) until tip of tool bit (20) touches micrometer spindle.


NOTICE

Do not sweep micrometer spindle across tool bit.



SETTING TOOL BIT
17. 1P2366 Tool Holder Assembly. 18. Shaft. 19. 9S8521 Rod. 20. Tool bit.

Use a maximum of .025 in. (0.64 mm) rough cuts and .010 in. (0.25 mm) finish cuts.

Wipe boring bar and tool holder clean. Place tool holder on the boring bar, with tool bit cutting edge facing the direction of rotation. Assemble the tool holder by placing lower half over the bolts, slide into slot and tighten bolts. Slide boring bar in until tool is approximately .12 in. (3.0 mm) from the bore. Compare tool cutting tip with bore surface while turning boring bar by hand, to insure correct tool setting.

Set feed mechanism into feed by turning knob (23) until pin (22) drops into slot (21).


FEED ENGAGED
21. Slot. 22. Pin. 23. Knob.

NOTE: To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).


LATER FEED MECHANISM
A. Lever.

Place adapter (24) into boring bar and tighten setscrew (25).


ADAPTER INSTALLED
24. 1P2364 Adapter. 25. Setscrew.

Apply layout bluing to the bearing cap and bearing bore. Oil the centering rings. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (26) to feed tool through the bore. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit the bore to be bored oversize. Bore the bore to 3.7175 ± .0005 in. (94.425 ± 0.013 mm).


BORING BEARING BORE
26. 1P2363 Universal.

NOTE: If you use the later feed mechanism, the tool can be driven from either the boring bar or the feed mechanism.


DRIVING THROUGH FEED MECHANISM (Typical Example)
26. 1P2363 Universal.

The bluing applied to the bearing bore indicates the condition of the bore at the correct bore size. If bluing shows an out of round condition, check the largest diameter (indicated by remaining bluing) in relation to the smallest diameter (indicated by lack of bluing). The difference of the two must not exceed .0010 in. (0.025 mm).

If bluing indicates a step in the joint face, measure the diameter at the step in relation to the smallest diameter. A step of .0005 in. (0.013 mm) on one or both sides is permissible. A maximum of .0010 in. (0.025 mm) over the nominal finish bore diameter is permissible if within the described limits.

To check the bore diameter, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).


CHECKING BORE (Typical Example)

Line Boring Main Bearing Bores

Line bore all main bearing bores if bearing caps or saddles are distorted.

Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.

Place 1P2344 Centering Rings (1), with oiler (2) up, at each end of block. If an end bore is distorted, use the next good bore.

NOTE: There must be two good bores for locating centering rings.


CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.

Place original bearing caps (4) over the centering rings (1). Tighten bolts (3) hand tight.


CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 4. Bearing caps.


BORING BAR INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 5. 1P2352 Boring Bar.

Oil boring bar (5) and insert it through centering rings (1). Tighten bolts (3) to a minimum of 20 lb. ft. (25 N·m) and a maximum of 50 lb. ft. (70 N·m) while spinning boring bar (5) to check for binding. Centering rings (1) must be seated in bearing saddles after tightening.

Slide boring bar (5) out of one end of block and install bearing assemblies (6) on boring bar (5). Slide boring bar (5) back through centering ring. Adjust bearing by tightening bolt (7) until bar begins to bind, then back off until boring bar (5) spins easily.


INSTALLING BEARING ASSEMBLIES
5. 1P2352 Boring Bar. 6. 1P2373 Bearing assembly (two). 7. Bolt.

Install bridge assemblies (8) over bearing assemblies (6). Position bridge assemblies (8) on block as shown with thicker portion up.

NOTE: Bridge assemblies must be on block as shown for tool holder clearance at each bore.


BRIDGE ASSEMBLIES INSTALLED
6. 1P2373 Bearing Assembly (two). 8. 1P2343 Bridge Assembly (two).

Tighten bolts (9) finger tight. Tighten bolt (10) lightly. Tighten bolt (11). Loosen, then tighten bolts (9) and bolt (10). Spin boring bar (5) during all tightening operations. Repeat above procedure if boring bar (5) binds.


BOLT LOCATION
9. Bolts (two). 10. Bolt. 11. Bolt.

Remove original bearing caps and centering rings. Mark new caps to correspond with numbers on saddle and install new service caps. Mark caps and saddles "OS" for oversize next to location number.

Be sure to install new bolts. Put crankcase oil on bolt threads and washer face. Tighten bolts in number sequence shown to 30 ± 3 lb. ft. (40 ± 4 N·m), put a mark on each bolt and cap. Tighten all bolts by number from mark an added 120° ± 5°.


(Typical Example) BOLT TIGHTENING SEQUENCE

Bolt torsion bar assembly (12) loosely to opposite end of block from which boring bar will be driven. Install feed assembly (14) into boring bar and tighten setscrew (13). Slide feed assembly (14) onto torsion bar assembly (12) and tighten bolt (15). Tighten bolt (16) finger tight. Boring bar must slide in and out freely after these tightening operations. Tighten thumbscrew (17).


FEED ASSEMBLY INSTALLED
12. 1P2369 Torsion Bar Assembly. 13. Setscrew. 14. 1P2365 Feed Assembly. 15. Bolt. 16. Bolt. 17. Thumbscrew.

Place adapter (18) into boring bar and tighten setscrew (19).


ADAPTER INSTALLED
18. 1P2364 Adapter. 19. Setscrew.

To set tool in tool holder. Set micrometer (21) to 3.7075 in. (94.171 mm). Place centering ring (1) on the 1P2370 Micrometer Bracket Assembly. Move micrometer (21) until spindle (20) contacts centering ring (1). Tighten bolt (22). Back off micrometer thimble and recheck micrometer setting. Repeat above steps until micrometer setting is accurate.


SETTING MICROMETER
1. 1P2344 Centering Ring. 20. Micrometer spindle. 21. Micrometer. 22. Bolt.

Place tool holder (23) on the 1P2370 Micrometer Bracket Assembly. Align mark on tool holder (23) with hole in shaft (24). Place tool bit (26) in tool holder (23) and set the micrometer .070 in (1.78 mm) less than the finish bore diameter of 3.7175 ± .0005 in. (94.425 ± 0.013 mm). Turn the bracket assembly arm until micrometer spindle aligns with tool bit (26). Adjust tool bit (26) by pushing it with the 9S8521 Rod (25) until tip of tool bit (26) touches micrometer spindle.


NOTICE

Do not sweep micrometer spindle across tool bit.



SETTING TOOL BIT
23. 1P2366 Tool Holder Assembly. 24. Shaft. 25. 9S8521 Rod. 26. Tool bit.

Use a maximum of .025 in. (0.64 mm) for rough cuts and .010 in. (0.25 mm) for finish cuts.

Wipe the boring bar and tool holder clean. Place tool holder on the boring bar, with tool bit cutting edge facing the direction of rotation. Assemble the tool holder by placing lower half over the bolts, slide into slot and tighten bolts. Slide boring bar in until tool is approximately .12 in. (3.0 mm) from the bore. Compare tool cutting tip with bore surface while turning boring bar by hand, to insure correct tool setting.


FEED ENGAGED
27. Slot. 28. Pin. 29. Knob.

Set feed mechanism into feed by turning knob (29) until pin (28) drops into slot (27).

NOTE: To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).


LATER FEED MECHANISM
A. Lever.

Oil the bearing assemblies. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (30) to feed the tool through the bores. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit bores to be bored oversize. Bore block to 3.7175 ± .0005 in. (94.425 ± 0.013 mm).


BORING BLOCK
30. 1P2363 Universal.


DRIVING THROUGH FEED MECHANISM (Typical Example)
30. 1P2363 Universal.

NOTE: If you use the later feed mechanism the tool can be driven from either the boring bar or the feed mechanism.

When boring, if bearing assemblies interfere or tool does not reach next bore, reposition tool holder on boring bar.


POSITIONING TOOL HOLDER

To check bores, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).


CHECKING BORE

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