b series cylinder bore salvage. 1995

8/20/2019 B Series Cylinder Bore Salvage. 1995

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e Service Bulletin

Subject 1263

B Series Cylinder Bore Salvage

1 Date: 1995

Bulletin No.3666131

This Service Bulletin is to document the proper procedures required to bore, sleeve, or hone a B Series cylinderblock.

General Service Information

Cylinder walls that are severely marred and/or worn beyond the specification limits should be refinished. Cylinderbore(s) can be repaired by two methods:

1. Over-boring and using oversize rings and pistons.

2. Boring and installing a repair sleeve to return to standard dimensions.

Oversize piston and rings are available in two sizes: 0.50 mm [0.0197 in] oversize, and 1.00 m [0.0393 in] oversize.Ifmore than 1.00 mm [0.0393 in] overbore is needed, a repair sleeve(s) is required. Itis permissible to install sleevesinto individual cylinders as required. Repair sleeves can be replaced by using a boring bar to bore out the cidsleeves. Do not cut the cylinder bore beyond the oversize limit.

NOTE:Repair sleeves áre not to be ovarbored for use withoversize pistons. Oversize pistons and rings can be intermixedin any combination in a cylinder block.

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NOTE: Before any cylinder is refinished, all main bearingcaps must be in place and tightened to the proper torque sothat the crankshaft bearing bares willnot become distortedfrom the refinishing operation.

Torque Value: Step 1. 60 N-m [ 44 ft-Ib]2. 119N-m [ 88 ft-Ib]3. 176 N-m [129 ft-Ib]

1. 60 N-m [44 tí-lb]

2. 119N-m [88 tí-lb]

3. 176 N-m [129tí-lb]

~Cleaning

Clean the cylinder block of all cid gasket material.

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Cummins Engine Company, Ine., Columbus, Indiana 47202-3005Cummins Engine Company Ltd., Daventry, Northants, England NN11 5NURegistered CHica: 46.50 Coombe Road, New Malden, Surrey KT3 4QLRegistered No. 573951 EnglandCopyright @ 1995Cummins Engine Company, Inc.Al! rights reservad

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B Series Cylinder Block Salvage

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Remove all lubricating oil galley plugs to allow cleaningsolution to contact the inside of lubricating oil passages.

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Warning: Follow the cleaner solution manufactures in-structions to avoid personal injury.

Remove grease and scale from the cylinder block byagitating in a bath of commercial cleaning solution or hotsoapy washing solution.

vWarning: When using a steam cleaner, wear protectiveclothing and safety glasses or a face shield. Hot steamwill cause serious personal injury.

Rinse the cylinder block in clean hot water to removecleaning solution.

Be gura to clean and dry all water passages, lubricating

oil passages, and drilled hojas.

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When rebuilding the angina, thoroughly inspect the cyl-inder block tor any condition that would make it untit torturther use. This inspection must be made atter sIl partshave been removed and the cylinder block has beenthoroughly cleaned and dried.

Make a thorough check tor cracks. Use a crack detectionkit, Part No. 3375432, to detect minuta cracks. It this kitis not available, use a mixtura ot 25% kerosene and 75%light lubricating oil. Wipe the part dry and immediatelyapply a coating ot zinc oxide (white lead), dissolved in

wood alcohol. It cracks are present, the white coating willbecome discolored at the detective ares. Always replacea cracked cylinder block.

vCheck sIl dowel pins, lubricating oil galley plugs, andexpansion plugs tor wear or damage and replace asnecessary.

Inspect sIl machined surtaces and threaded hojas. Care-tully remove any nicks or burrs trom machined surfacesusing a tlat oil stone. Clean out tapped hojas and cleanup any damaged threads. .

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Cylinder BoreOut of RoundMore than

O.38mm[0.0015in.]

Cylinder Bore

Taper More than0.076mm [0.003 in.]

Check the top ot the cylinder block tor tlatness with astraight edge and a teeler gauge. This surface is thecritical ares tor sealing lubricating oil, coolant, and com-pression. The overall tlatness, end to end and side to side,must not exceed 0.075 mm [0.003 in]. It warped, thecombustion deck can be resurtaced twice. The tirst re-

faca should be 0.25 mm [0.0098 in]. Itadditional re-tacingis required, an additional 0.25 mm [0.0098 in] can beremoved. Total allowed re-tacing is 0.50 mm [0.197 in].

The appropriate thickness head gasket must be usadafter the combustion deck has been resurtaced. Consult

the parís book tor the correct part number.

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Cylinder Bore Inspection

Inspect the cylinder bares tor scutting, scratches, wear,and scoring. Itthe cylinder bares are scuffed, scratched,scored, or worn, the cylinder bares must be re-bored andhoned tor the next oversize piston.

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Check the cylinder bore tor out-ot-round and tapar. Mea-gura the diameter ot each cylinder bore at the top, middle,and bottom with a bore gauge placed at right angles andparallel to the cantar line ot the angina.

Subtract the smallest dimension from the largest at eachlevel to determine out-of-round. Subtract the smallest

dimension form the largest in each direction top to bot-tom, to determine tapar.

Ifthe cylinder bore out-ot-round exceeds 0.38 mm [0.0015in], or cylinder bore tapar exceeds 0.076 mm [0.003 in],

the cylinder block must be re-bored and honed to the nextsize overbore piston.

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NOTE: Before any cylinder bore is refinished, all the mainbearing caps must be in place and tightened to the propertorque so that the crankshaft bearing bares will not becomedistorted from the refinishing operation.

Torque Value: Step 1. 20 N-m [ 44 ft-Ib]2. 119 N-m [ 88 ft-Ib]3. 176 N-m [129 ft-Ib]

Warning: During the machining process, wear protec-

tive clothing and safety glasses or a faca shield. Ma-chining debris can cause personal injury.

Boring should be done by qualified personnel on a suit-able boring machina. Cara should be taken to make sure

the cylinders are perpendicular to the combustion deckand within the tapar and out-of-round specifications forthe cylinder bore.

Follow the boring machina manufacturer's recommenda-tions for machina setupto achieve the best quality bore.

The boring diameter dimensions are as follows:

First re-bore 102.469 mm [4.0342 in]Second re-bore 102.969 mm [4.0539 in]

B Series Cylinder Block SalvagePaga 5

1. 60 N-m [44 ft-Ib]

2. 119 N-m [88 ft-Ib]

3. 176 N-m [129ft-Ib] 1)

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These dimensions are 0.050 mm [0.002 in] below the final honed dimension. Maximum cutting depth should belimitad to 0.228 mm [0.009 in] par cut. The remaining 0.05 mm [0.002 in] will be removed in the honing operation.

Alter boring, use a honing stone to break the edge of thebore to approximately 1.25 mm [0.049 in] x 15 degrees.

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i 1.25mm

[0.49 in.]

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Series Cylinder Block Salvageaga 6.

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1 Stroke

(t+~)Par Second

Finishing Hone285Grit

MinorGrooves

or Taper

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Sizing Hone80 Grit

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Honing Operation

The B Series angina requires a quality surtace tinish torthe engine's pistons and rings. This tinish can best beprovided by using two stage honing with quality equip-maní intended tor honing angina cylinder bares. Use ot aball-type hone is only recommended tor retinishing cyl-inder walls that do not need re-boring.

Honing Diameter Dimensions:

Standard Bore 102.020 :!: 0.020 mm

[4.0165 :!: 0.0008 in]First Re-bore 102.520 :!: 0.020 mm

[4.0362 :!: 0.0008 in]Second Re-bore 103.020 :!: 0.020 mm

[4.0559 :!: 0.0008 in]

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Honing Machine Tool Set Up

A. Honing rotational speed 300 RPM to 400 RPM.

B. Honing stroke trequency 1 stroke (i + J.,)/second.

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C. For tirst stage honing, or rough honing, use a soft(tast-cutting) 80 grit silicon carbide stone.

D. For second stage honing, or tinish honing, use a me-dium hardness 285 grit silicon carbide stone.

Honing Procedure:A. Hone the cylinders to their final size during the rough

honing stage. Use a commercially available honing oilor, a mixtura ot equal parís 30W angina oi! and dieseltuel tor a honing lubricant.

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B. Check the diameter of the cylinder bore regularly dur-ing honing. Use a dial bore gauge and check the sizeat six placas in the bore, measuring at the top, middleand bottom, 90 degrees aparto

C. Finish hone by installing the finishing hones (285 grit)intothe cylinder and expand until snug. Then hone for15 to 20 additional strokes at the 1 stroke par secondfeed rata.

D. A correctly honed surface will haya a crosshatchedappearance with the lines at 15 to 25 degree angleswith the top of the cylinder block. A 1.2 maximum

micrometer (48 microinch) surface finish must beobtained.

E. Immediately clean the cylinder bares with a strongsolution of laundry detergent and hot water. After rins-ing, blow the cylinder block completely dry.

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Finishing Hone285 Grit

15 lo 20Addilional

Strokes

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B Series Cylinder Block Salvage .

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102.020 :!:0.020 mm

[4.0165 :!:0.0008 in.]

3904166

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F. Check the cylinder bore cleanliness by wiping with awhite, lint-free lightly oiled cloth. If grit residue is stillpresent, re-clean. J

G. If the cylinder block is not to be usad right away;"coatwith a rust preventative solvent.

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Repair Sleeve Installation

If more than 1.00 mm [0.0397 in] diameter oversize boreis required, the cylinder block must be re-bored and a

repair sleeve, Part No. 3904166, installed. The sleevebore must be refinished after installation to standard di-ameter, 102.020 :t 0.020 mm [4.0165 :t 0.0008 in]. Astandard diameter piston and service piston ring set mustbe usad. Using overbore pistons in a sleeved cylinder isnot allowed.

Re-bore cylinder requiring sleeve using procedure listedabove te:

Diameter

104.500 + 0.015 mm [4.1142 + 0.0006 in]104.500 - 0.000 mm [4.1142 - 0.000 in]

Depth from the combustion deck:192.65 mm [7.5846 in]

This should result in a 6.35 mm [0.25 in]step at the bottomof the cylinder against which the sleeve will seat. v



After boring, thoroughly clean the bore ot all metal chips,debris and oil betore installing the repair sleeves.

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Freeze the repair sleeve(s) tor a minimum ot one hour ata temperatura at or below -12°C [+ 10°F]. Remove thesleeves one at a time and install in the cylinder block using the tollowing procedure:

Apply a coat ot LoctiteTM620 to the top ot the bore, one ata time as the sleeve is installed.

Wearing protective gloves, push the trazan sleeve into thebore as tar as possible by hand.


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Hone the cylinder to the standard bore dimension. Usethe honing process listed in the previous procedure.


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b series cylinder bore salvage. 1995

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