Media Search - SEHS8869 - Cylinder Block Salvage Procedure Using Belzona Ceram... ??? . 1 ??10 Shutdown SIS Previous Screen Product: NO EQUIPMENT SELECTED Model: NO EQUIPMENT SELECTED Configuration: NO EQUIPMENT SELECTED Special Instruction Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal Media Number -SEHS8869-03 Publication Date -02/07/2002 Date Updated -02/07/2002 SEHS88690001 Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal SMCS - 1000 SEHS8869-03 July 2002 SPECIAL INSTRUCTION Cylinder Block Salvage Procedure Using Belzona® Ceramic R Metal SMCS Code: 1201 Summary of Revisions Page Description All Updated information. Table of Contents Introduction 1 References 1 Tooling and Equipment 1 Examples of Erosion 2 https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si... 18.01.2006 . These cast iron cylinder blocks have been damaged by cavitation erosion.Cylinder Block Salvage Procedure Using Belzona Ceram. 18. References Reference Material Form No Title SEBF8157 Specifications for Cylinder Blocks 3500 Family of Engines Tooling and Equipment Tooling and Equipment Part No Description 1U-5789 Needle Scaler Attachment for Pneumatic Tools 8T-9011 Component Cleaner 4C-4079 Brake & Electrical Cleaner 9U-6346 Component Cleaner https://sis..2006 . contact Caterpillar Service Support Division.com/sisweb/sisweb/techdoc/techdoc_print_page. For questions or additional information concerning this Special Instruction. ??? . Dealer Support (309) 636-5833.01. Refer to "Examples of Erosion" in this Special Instruction for the type of erosion that can be repaired with this procedure..SEHS8869 .. Note: Do not perform any procedure in this Special Instruction until you understand the information.Media Search .cat. 2 ?? 10 Surface Preparation 2 Application of the Repair Material 3 Mixing the Repair Material 3 Surface Finishing of the Repaired Area 5 Ordering the Repair Material 6 North America 6 Europe 6 Introduction This Special Instruction provides the procedure and the necessary materials for the salvage of cylinder blocks.jsp?returnurl=/sisweb/si. Media Search ... https://sis.cat.SEHS8869 . 3 ?? 10 Examples Of Erosion Illustration 1 and Illustration 2 show the types of erosion that can be repaired with the use of the Belzona® Ceramic R Metal. Surface Preparation After all machining or salvage work has been completed the cylinder bore must be thoroughly cleaned.Cylinder Block Salvage Procedure Using Belzona Ceram. Note: The cylinder block must NOT be put in a caustic cleaning solution after the Belzona® repair material has been applied. 18. Illustration 1 Pitting has occurred in the cylinder bore (head bolt boss)..2006 .jsp?returnurl=/sisweb/si. Illustration 2 Pitting has occurred in the sidewall of the cylinder block.01. ??? ..com/sisweb/sisweb/techdoc/techdoc_print_page. Refer to Illustration 4.. 4 ?? 10 Illustration 3 Deep pitting has occurred within the cylinder liner bore.Media Search . Excessive force may cause breaks and cracks in the thin wall. https://sis. 1. If the eroded area contains deep pitting.com/sisweb/sisweb/techdoc/techdoc_print_page. NOTICE Do NOT apply excessive force against the thin wall section of a cylinder block. 18. all corrosion must be removed from the pitted area.cat.SEHS8869 .01.Cylinder Block Salvage Procedure Using Belzona Ceram..jsp?returnurl=/sisweb/si. Refer to Illustration 3. ??? .. Illustration 4 Pitting is removed with a pneumatic needle scaler.2006 .. This removal process can be manually performed by using an ice pick or by using a pneumatic needle scaler. com/sisweb/sisweb/techdoc/techdoc_print_page.00 inch) around the outer edge of the damage. NOTICE Oil base cleaners must NOT be used because they leave an oily film. remove additional metal as necessary to permit a slight build-up with the Belzona® repair material. again apply the cleaner/ degreaser.cat.01. Allow the tool to bounce slightly in order to produce the maximum roughness. After the required finish of the surface has been obtained. A power tool that comes in contact with this area will result in an improper seal around the cylinder liner. 2. Do NOT remove more than 3. clean the area that will be repaired. Use a clean shop towel in order to check the cleanliness of the area that will be repaired.2006 ..SEHS8869 . This grinding can usually be done with an electric grinder and a medium coarse carbide bit or with a rotary file. After the corrosion has been removed. ??? .jsp?returnurl=/sisweb/si.125 inch) of the base material. 5. Note: All dirt and oil residue MUST be removed.Media Search . Repeat the cleaning procedure until the area is completely clean. If the section to be repaired has limited clearance with a cylinder liner.. 18.. Allow the cleaner/degreaser to dry without contacting the surface again. 4. 3. Use the cleaner/degreaser to thoroughly clean the area that will be repaired. Apply light pressure only.Cylinder Block Salvage Procedure Using Belzona Ceram. https://sis. NOTICE Do NOT permit any power tools to come in contact with the cylinder liner seat area. After the final check for cleanliness has been performed. The feel of the surface is similar to medium grade sandpaper. Note: Do NOT grind all the way through the cylinder block. 5 ?? 10 Illustration 5 The area has been ground so that the surface appears dull. grind the entire repair area..1 mm (0. The grinding will provide a rough finish for good adhesion for the repair material.4 mm (1. This oily film will prevent the repair material from adhering to the cylinder block. Grind an additional 25. To make the repair material. The repair material should be spread apart. The repair material will require additional time to solidify at cooler temperatures. read and make sure you understand the manufacturer’s Material Safety Data Sheets enclosed with the repair material. Refer to the "Temperature and Time" chart included with the Belzona repair material. Note: The time that is required for the repair material to solidify will vary according to the ambient temperature. 1.2006 . Application of Repair Material Mixing The Repair Material The repair material will not harm the skin under normal circumstances. The repair material will solidify faster at warmer temperatures.Media Search . 18. To prevent any possible injury. 3. Next..01.com/sisweb/sisweb/techdoc/techdoc_print_page.cat. NOTICE The recommended solidification mixture (with the ratio of one part to three parts) must NOT be exceeded. Incorrect mixing of the repair materials will result in a reduction in the final strength of the repair. Mix one part solidification mixture to three parts (by volume) of the base material. Before using the repair material. ??? . it is recommended that rubber gloves be worn.jsp?returnurl=/sisweb/si. 2.SEHS8869 . The repair procedure that was stated in this Special Instruction was performed at a temperature of 20°C (68°F). https://sis. 6 ?? 10 Note: The finish of the surface and the cleanliness of the surface are essential for a successful repair... This method allows time for the application of the repair material before it hardens and becomes difficult to apply.. Repeat the process of spreading apart and folding together until complete mixing is achieved. The ambient temperature determines the time that is required for the repair material to solidify. use the supplied tools or use a clean putty knife. The repair material is completely mixed when a consistent color is achieved. the repair material should be folded together.Cylinder Block Salvage Procedure Using Belzona Ceram. Mix the repair materials only in small amounts. 5.Media Search .Cylinder Block Salvage Procedure Using Belzona Ceram. Repair material that is spread apart will slow the amount of time that is needed for the repair material to cure. Illustration 7 Repair material does not extend beyond the area that has been prepared and cleaned.. the excess repair material will increase the grinding time in the finishing procedure. Adherence to this rule should be maintained until additional experience with the characteristics of the repair material is achieved. Note: Do NOT place the repair material in a pile.SEHS8869 ..com/sisweb/sisweb/techdoc/techdoc_print_page. Note: No more than two cylinder liner bores should be repaired at the same time. Next small amounts of the repair material are applied into any holes or pitted areas.01.jsp?returnurl=/sisweb/si.2006 . The repairable sections are identified. Illustration 6 Repair material is applied into the holes and into the pitted areas. A thin layer of the repair material is applied in order to build up the repaired area to the original dimension. Place special attention on the clearances of the cylinder liner during the building up of the repair material. There is a tendency to apply too much of the repair material.cat. When too much repair material is applied. https://sis. ??? . 18.. 4. 7 ?? 10 This method is preferred to a method that uses stirring motion.. The repair material is firmly applied in order to remove any air pockets that may have formed. the repair material blends into the surrounding metal. do NOT contaminate the inside of the oil gallery with excess repair material. 3. NOTICE Use only enough water to wet the glove. 2.. Surface Finishing the Repaired Area 1. The surface may also be somewhat sticky. The surface may look like a dried film.01. After approximately 30 minutes from the original mixing time.SEHS8869 .Media Search . If the repair material sticks to the finger of the glove. Dip the fingers of your glove in water.. a smooth finish is not necessary. In this way. The correct result will reduce the required time to grind once the Belzona repair https://sis.. 8 ?? 10 Make sure that you taper the edges of the repair material. the applied repair material can be smoothed. NOTICE When repairing an area that has eroded into an oil gallery.. The check will determine the condition of the surface.2006 . ??? . Do not go beyond this area that has been prepared and cleaned! Any repair material that mistakenly extends beyond this area must be removed. Any repair material that is pressed through a hole and into the oil gallery MUST be removed. Put on rubber gloves and check the surface of the repair material. Press firmly in order to expel any air that may have been trapped in the repair material during the smoothing process. the repair material is too wet. The repair material will NOT adhere to an unprepared surface of the base metal. Rub the surface of the repair back and forth in order to get a smooth finish of the repair material at the repaired area. When the repair material is being applied.jsp?returnurl=/sisweb/si.Cylinder Block Salvage Procedure Using Belzona Ceram.com/sisweb/sisweb/techdoc/techdoc_print_page. The procedure "Surface Finishing of the Repaired Area" within this Special Instruction will provide instructions on the ability to attain the smooth finish.cat. Too much water on the Belzona repair material can have an adverse effect on its mechanical strength. 18. the cylinder block can be assembled.jsp?returnurl=/sisweb/si. ??? . Some caustic solutions. The cylinder block can now be cleaned with steam in order to remove the debris that remained after the grinding procedure. contact one of the following offices: North America https://sis. can damage the repair material. Note: When the Belzona Ceramic R Metal is correctly mixed and used at a temperature of 21°C (70°F).2006 .. To locate the distribution that is nearest to you. Ordering The Repair Material The Belzona Ceramic R Metal must be ordered from one of the Belzona worldwide distributors. the repair material will develop full mechanical capabilities in 24 hours.cat. grind away enough material in order to return the piece back to the original dimensions.com/sisweb/sisweb/techdoc/techdoc_print_page. at higher temperatures. 4.. 9 ?? 10 material has cured.. In those areas that have close clearances. Other areas should be left with a slight buildup of the repair material for resistance to future erosion.Media Search .Cylinder Block Salvage Procedure Using Belzona Ceram.SEHS8869 .01. 18. NOTICE Do NOT place the cylinder block on a hot caustic tank after this type of repair has been performed. 5. After the repair material has been applied for two hours. After the cleaning procedure is completed. Illustration 8 The finish grind of the repaired area has been performed on the repair material. the repair material should be hard enough for the finish grind.. North Yorkshire HG1 4AY.. America's Gateway Park 2000 N. Cairo Road. Inc. 18.cat. Harrogate..2006 Caterpillar Inc..W. Wed Jan 18 11:55:28 UTC+0300 2006 All Rights Reserved. https://sis. 10 ?? 10 Belzona America.SEHS8869 . 88 Court Miami.Media Search . Private Network For SIS Licensees.01.2006 .. England Telephone: 011 44 (1423) 567641 Telex: 57938 Fax: (01423) 505967 Copyright 1993 .Cylinder Block Salvage Procedure Using Belzona Cer. FL 33172 Telephone: (305) 594-4994 Toll-free: (800) 545-0456 Telex: 645549 Fax: (305) 599-1140 Europe Belzona Molecular.jsp?returnurl=/sisweb/si. ??? . LTD.com/sisweb/sisweb/techdoc/techdoc_print_page.
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