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Best Practice submission form

Please fill in the appropriate information:


DATE: 3/9/2009

BEST PRACTICE TITLE 3500 Engine Block Salvage - Water Ferrule Inserts

SUBMITTER NAME Dale Brehm

PHONE NUMBER -54583

EMAIL ADDRESS brehm_dale_e@cat.com

COMPANY Cat

DEALERSHIP Various

MINE SITE N/A

REGION NACD

Does Caterpillar Global Mining require additional Yes


authorization to publish/ share this Best Practice? No

Please submit to:


Caterpillar Global Mining Best Practices Process Owner: Joe Schell

Email: schell_joe_r@cat.com,
Phone 309.494.4447, Fax 309.675.4616

CGM BEST PRACTICE STAFF ONLY


BP Number:

Category (main): Component Rebuild

Category (secondary): Salvage - Tactical

Site Assessment items:


BEST PRACTICE SERIES

3500 Engine Block Salvage


- Water Ferrule Inserts
Site Component MARC
Application Maintenance Safety
Management Rebuild Management

3500 Engine Block Salvage - Water Ferrule Inserts ..0


1.0 Introduction........................................................1
2.0 Best Practice Description ..................................2
3.0 Implementation Steps........................................4
4.0 Benefits .............................................................5
5.0 Resources Required..........................................6
6.0 Supporting Attachments / References ...............6
7.0 Related Best Practices ......................................6
8.0 Acknowledgements ...........................................6

April 09
0906-4.5-1013
300 Hamilton Blvd., Ste. 300, Peoria, IL 61629-3810, U.S.A. catminer.com
CAT GLOBAL MINING BEST PRACTICE SERIES

1.0 Introduction

Caterpillar has recently released a Special Instruction SEBF8263 that details a procedure to
salvage 3500 series engine blocks with pitting in the water ferrule areas. The Special Instruction
is attached. This is a procedure to drill out the damaged / pitted area with an end mill bit and
install a stainless steel insert.

There are several methods to salvage block surfaces with pitting in the water ferrule and water
seal area. Often dealers will mill the entire top deck surface enough to remove the pitting. This
procedure is an effective repair, but shortens the number of times a block can be reused due to
the reduced block height.

Caterpillar does offer a salvage process for this area using Belzona to repair the surface, but this
is not a long-term fix.

Repairing a pitted block during the first rebuild by installing stainless steel inserts in all the water
ferrule areas will reduce future pitting and future need for machining and salvage. This may add
one or more additional life cycles to the engine block

Figure 1. Pitted water ferrule area

Block Inserts.docTHE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Title 4/3/2009 0000-1.1-1001
00
CAT GLOBAL MINING BEST PRACTICE SERIES

Figure 2. Engine block salvaged with stainless steel inserts

While some Caterpillar dealers use a Rottler machining center to cut the counterbores for the
inserts, the process can be performed with a large radial drill and milling template. Even with the
additional steps involved, this process provides a cost effective method for those dealers without
large CNC vertical mills.

2.0 Best Practice Description

To implement and use this salvage procedure is a matter of following the Special Instruction
SEBF8263. However, there are two key elements of this Best Practice regarding when and how
to use the salvage procedure.

Some dealers, as a standard practice, automatically install stainless steel inserts in all the block
water ferrules (8 per cylinder) at the first rebuild. This is done even if the majority of the ferrules
do not show signs of pitting.

The benefit of this practice is that, after inserts are installed, the block top deck is only machined a
few thousands of an inch. In future rebuilds, the need to machine the block is greatly reduced or
eliminated.

Block Inserts.docTHE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Title 4/3/2009 0000-1.1-1001
00
CAT GLOBAL MINING BEST PRACTICE SERIES

Without the use of inserts, it is often necessary to machine the block .010 or more to remove the
pitting. After a second rebuild, the block deck height is often at minimum height and cannot be
used again without spray welding the entire deck.

Using the steel inserts on the first rebuild can add one or more life cycles to the engine block.

A second feature of this Best Practice is that the salvage can be performed without the need of
expensive machining tools, such as a Rottler or CNC. This procedure is performed with a vertical
drill.

Block Inserts.docTHE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Title 4/3/2009 0000-1.1-1001
00
CAT GLOBAL MINING BEST PRACTICE SERIES

3.0 Implementation Steps


Follow Special Instruction Procedure
Fabricate a template to position and guide the drill end mill. Template is patterned from the
cylinder head gasket.

Note template has bushings to guide the drill end bit and pins to position and lock the template
to the block deck.

Block Inserts.docTHE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Title 4/3/2009 0000-1.1-1001
00
CAT GLOBAL MINING BEST PRACTICE SERIES

Caterpillar offers large (30mm) and small (20mm) stainless steel inserts as a serviced part
number. Specification and part numbers are contained in the Special Instruction. The inserts
are a 416 steel for easier machining. Procedure requires a 20mm and a 30mm end mill bit.

Complete the procedure following the Special Instruction.

4.0 Benefits

Eliminate future pitting in the water port areas.


Reduce/eliminate block deck machining on later rebuilds
Lower machine shop investment. CNC machines are not required
Reduce rebuild turnaround time.
Add additional life cycles to the block. Saves $40,000+ over block replacement (3516).

Block Inserts.docTHE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Title 4/3/2009 0000-1.1-1001
00
CAT GLOBAL MINING BEST PRACTICE SERIES

5.0 Resources Required

Investment costs vary depending on what machining capability dealer already has:
o Radial drill press and block supporting stands
o Surface milling machine
o End milling tools
o Counterboring and drilling templates (fabricated as needed)
People
o Establish standard job/process with team
Training
o Establish the salvage benefits with the production team
o Train machinists in process and quality expectation
.

6.0 Supporting Attachments / References

7.0 Related Best Practices

None.

8.0 Acknowledgements

Photos are from Ferreyros, Lima Peru

Block Inserts.docTHE INFORMATION HERON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED.

DATE CHG
NO NUMBER
Title 4/3/2009 0000-1.1-1001
00

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