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Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 and ...
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produtos: WHEEL LOADER
Modelo: 924F WHEEL LOADER 4YN
Configurao: 924F Wheel Loader 4YN00001-UP (MACHINE) POWERED BY
3114 Engine
Diretrizes para Reutilizao e Recuperao

Installing a 7C-6208 Cylinder Sleeve in 3114 and 3116 Engines and a 107-7604 Cylinder
Sleeve in 3126 Engines
Nmero de Mdia -SEBF8261-03
Data de Publicao -10/10/2002
Data de Atualizao -10/10/2002

SEBF82610001
Installing a 7C-6208 Cylinder Sleeve in 3114 and 3116 Engines and

a 107-7604 Cylinder Sleeve in 3126 Engines
SMCS - 1222
SEBF8261-03
September 2000
SMCS Code: 1222
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE
OPERATIONS
Installing a 7C-6208 Cylinder Sleeve in
3114 and 3116 Engines and a
107-7604 Cylinder Sleeve in 3126 Engines
Summary of Revisions
Page
All
Description
Information and illustrations have been revised
throughout this guideline.
Introduction
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Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 and ... Page 2 of 15
This Guideline enables dealers and their customers to benefit from cost reductions made possible
through an established parts reusability and salvage program. Every effort has been made to
provide the most current and relevant information known to Caterpillar Inc. Since the Company
makes ongoing changes and improvements to its products, this Guideline must be used with the
latest technical information available from Caterpillar to ensure such changes and improvements
are incorporated where applicable.
For questions or additional information concerning this Guideline, contact Caterpillar Service
Support Division, Dealer Support (309) 675-5487.
Summary
The 7C-6208 Cylinder Sleeve is available for reconditioning the cylinder blocks used in 3114 and
3116 Engines. The 107-7604 Cylinder Sleeve is available for 3126 Engines. Use the cylinder
sleeves when it is determined that the existing cylinder wall(s) are not reusable because of wear,
pin holes, cracks, or scoring.
Inspect the cylinder block carefully to be sure it is still usable. If sleeves are to be installed, use the
procedure given in this Guideline.
If the dimension of a cylinder, or cylinders, is to be accurately measured, a 4C-4377 Stress Plate
Group (3114/3116) or 126-8132 Cylinder Head Stress Plate (3114/3116) and a STANDARD
thickness cylinder head gasket must be installed over each cylinder that is to be measured. For
3126 Engines, use a
142-2285 Stress Plate (3126) or a 125-2064 Cylinder Head Stress Plate (3126).
When used in the same application, parts that meet the "Use again" specifications in this Guideline
can be expected to give normal performance until the next overhaul.
Never install a part that this Guideline shows cannot be used again. During reconditioning, correct
any conditions that might have caused the original failure.
Tooling and Equipment

The chart that follows lists the boring tools, and the honing machines, that are acceptable and/or
recommended to perform the procedures given in this Guideline.
Required Tools
Part Number
3114/3116
Part Description
3126
Boring and Honing Equipment1
Rottler Model F2VB
Rottler Model FA2AVB
Sunnen CK-10
Sunnen CV-616
Rottler HP3
Rottler HP3A
Sleeve Installation Tools
1P-0820
9S-6074
6V-2183
1P-2329
9S-6072
9S-7338
1P-0820
9S-6074
6V-2183
1P-2329
9S-6072
9S-7338
Hydraulic Puller Group

Adjusting Screw (not used)
Forcing Screw
Insert
Adjusting Crank
Cross Block (not used)
9U-6007
129-9197
Puller Plate
9U-6008
129-9196
Puller Plate
1D-5119
1D-5119
Nut
5H-1504
5H-1504
Washer
Tools for Honing Procedure

4C-43772
142-22852
Stress Plate Group
126-81322
125-20642
Cylinder Head Stress Plate
1P-3565
1P-3565
Chamfering Group
Cleaning Tools
1P-5580
1P-5580
Brush Group
1U-7429
1U-7429
Brush
1Any
of the following tools are acceptable for use in this procedure.
2Stress
plate is used only during measuring and honing of the cylinder sleeve bore. Do not use the stress plate during the block boring procedure.
Boring and honing equipment can be purchased from the manufacturers below.
Rottler Manufacturing
8029 South 200th St.
Kent, WA 98032 USA
Phone: (253) 872-7050
Fax: (253) 395-0230
Sunnen Products Co.
7910 Manchester Ave.
St. Louis, MO 63143
Phone: (800) 325-3670
Fax: (314) 781-2268
Note: In addition to the tools listed in the chart, a STANDARD thickness cylinder head
gasket for both the 3114 and 3116 Engine, must be used with the 4C-4377 Stress
Plate Group or 126-8132 Cylinder Head Stress Plate, during the honing cycle. A
standard thickness cylinder head gasket for the 3126 Engine must be used with the
142-2285 Stress Plate Group or 125-2064 Cylinder Head Stress Plate during the
honing cycle. The cylinder head gasket may be reused several times with the stress
plate, however a new gasket must be used during the final cylinder head installation.
Refer to the Parts Manual for the correct STANDARD thickness cylinder head gasket.
When replacement parts are required for

this product Caterpillar recommends
using Caterpillar replacement parts or
parts with equivalent specifications
including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to
premature failures, product damage,
personal injury or death.
Machining Procedure and Specifications
Illustration 1
Machining specifications for bore in block. Refer to Chart A for item identification and specifications.
Note: The stress plate group or the cylinder head stress plate is ONLY used when
measuring the bores or performing the honing procedure. The stress plate is not used
during block boring procedure. Refer to Chart B for stress plate group or cylinder head
stress plate part numbers.
Chart A.
Bore in Block Machining Dimensions
Item
Description
7C-6208 Cylinder Sleeve (3114/3116)
107-7604 Cylinder Sleeve (3126)
Original Cylinder Bore Diameter
Original Cylinder Bore Diameter
109.732 0.013 mm (4.3201 .0005 in)
114.775 0.013 mm (4.5187 .0005 in)
196.77 0.13 mm (7.747 .005 in)
196.85 0.08 mm (7.750 .003)
0.3 mm (.01 in) x 45 degree radius
2.3 mm (.09 in) x 10 degree radius
E
0.5 mm (.02 in) x 45 degree chamfer
1.5 mm (.06 in) x 45 degree chamfer
Note: Refer to Illustration 1 for item callouts.
Chart B.
Stress Plate Part Numbers
Engine
Stress Plate
Stress Plate Group
3114/3116
4C-4377
126-8132
3126
142-2285
125-2064
Position boring tool on cylinder block.

Note: Dimension (A) is the diameter of the original bore.
1. Use the centerline of the original cylinder bore (A), and machine the bore to diameter (B) and
depth (C). The new bore must be within 0.05 mm (.002 in) total runout with the centerline of
original cylinder bore (A).
Note: Dimension (C) is measured from the top deck (top surface) of the cylinder block.
2. Remove the sharp corner and any burrs at the bottom edge of bore (E).
Installation of Cylinder Sleeve
Illustration 2
Cylinder sleeve installation tooling.
Chart C.
Item Identification
Part No.
Item
Description
3114/3116
3126
Forcing Screw
6V-2183
Insert
1P-2329
Hydraulic Puller
Group
1P-0820
4
Puller Plate
9U-6008
129-9197
Cylinder Sleeve
7C-6208
107-7604
Puller Plate
9U-6007
129-9196
Nut
1D-5119
Adjusting Crank
9S-6072
Washer
5H-1504
1. Remove the 9S-6074 Adjusting Screw from hydraulic puller group (3) and install forcing
screw (1) in its place.
2. Use hydraulic puller group (3) with forcing screw (1), insert (2), puller plate (4), puller plate
(6), washer (9), nut (7), and cylinder sleeve (5) as shown in Illustration 2
Note: Install the cylinder sleeve (5) with the 10 outside diameter chamfer toward the
cylinder block.
3. Put clean diesel fuel (No. 2) on the outside diameter of cylinder sleeve (5).
4. Connect a hydraulic pump to hydraulic puller group (3) and pull cylinder sleeve into the bore.
5. Reposition the hydraulic puller group.
a. Retract hydraulic puller group (3).
b. Loosen the socket head screw and readjust insert (2).
Note: Insert (2) will need to be readjusted several times before the sleeve is fully
installed.
Illustration 3
Cylinder sleeve (5) is installed and has complete contact (10) with bottom of bore.
6. Pull cylinder sleeve (5) into the bore until the bottom of the sleeve contacts the counterbore
at location (10).
Illustration 4
Cylinder sleeve specifications.
Chart D.
Inserted Cylinder Sleeve Specifications
Item
3114/3116
3126
1.02 0.25 mm
(.040 .010 in) chamfer
1.02 0.25 mm
(.06 .02 in) chamfer
30 degree angle
30 degree angle
Maximum height above top

deck surface
[0.013 mm (.0005 in)]
Maximum height above top

deck surface
[0.013 mm (.0005 in)]
7. After cylinder sleeve (5) is installed in the cylinder bore, it is acceptable for the top of the
cylinder sleeve to extend a maximum of 0.013 mm (.0005 in), (H, Illustration 4), above the
cylinder block top deck. For best installation results, the cylinder sleeve should be flush with
the top deck of the cylinder block.
Note: It is acceptable to machine the top of the cylinder sleeve, so it is even with the
cylinder block top deck.
NOTICE
If the top of the cylinder sleeve is
machined, do NOT nick or cause
damage to the top deck of the cylinder
block.
To ensure a correct seal between the
bottom of the cylinder head and the top
surface of the cylinder block near the
cylinder sleeve, the cylinder head gasket
MUST have a smooth surface to seal
against.
Illustration 5
Machine chamfer (F) on top of cylinder sleeve (5).
(11) Blend from chamfer (G) to bore of sleeve using flexible hone.
8. For 3114, 3116, and 3126 Engines, after the sleeve is inserted into the bore, machine a
chamfer as show in Illustration 5.
9. Use the 1P-3565 Chamfering Group to remove the sharp corner at the bottom of each
cylinder bore. The chamfer must be approximately 2.3 mm (.09 in) x 15 degrees. The
chamfer is necessary to prevent scuffing of the piston skirt.
Stress Honing Procedure

Installation of Stress Plate
The correct installation of the STANDARD thickness cylinder head gasket, stress plate group or
cylinder head stress plate, and cylinder head bolts will cause the cylinder bore to distort and have
the same dimensions that it would have if the cylinder head was installed and properly tightened.
Refer to Chart B for stress plate group or cylinder head stress plate part numbers.
The gasket and stress plate must be installed to accurately measure or finish hone the cylinder
sleeve. If a stress plate group is used, it must be installed over each cylinder.
Illustration 6
Cylinder head stress plate (1).
Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 a...
Page 10 of 15
Illustration 7
Cylinder head stress plate (1) installed on block (5) with STANDARD gasket (4) using bolts (2) and washers (3).
1. Install a STANDARD thickness cylinder head gasket (4) on cylinder block (5).
Note: The head surface of the cylinder should contain dowels to position cylinder head
gasket (4).
2.
3.
4.
5.
Position stress plate (1) over cylinder head gasket (4).

Install (original) cylinder head bolts (2) through the stress plate into cylinder block.
Initially tighten all bolts (2) evenly to 150 15 Nm (110 11 lb ft).
Finish tightening all bolts (2) evenly to 435 20 Nm (320 15 lb ft).
Honing Procedure
Finished bore dimension measurements must be made with the stress plate installed. The stress
plate is to make sure that the correct cylinder dimensions are maintained after the cylinder head is
installed.
1. After the stress plate group is correctly installed (as shown in Illustration 7) proceed with the
honing operation.
Note: For the correct honing specifications, use Chart E or Chart F, depending on the
honing/boring machine being used.
2. Hone the sleeve to obtain a cross hatch pattern (7, Illustration 8) with an angle of 140 10
degrees (I, Illustration 8). The cross hatch scratch pattern must be the same in both
directions.
Honing grooves (L, Illustration 9) must be 0.025 to 0.050 mm (.001 to .002 in) deep, and surface
(K, Illustration 10) must be 40 to 65 percent of the surface.
The scratch pattern must also be free of any material that can bend over and close the open area
of honing grooves (L).
Page 11 of 15
Illustration 8
Cross hatch pattern and finished bore diameter.
(7) Cross hatch pattern
(I) 140 10 degrees.
(J) 3114 and 3116 Engines: 105.025 0.025 mm (4.1348 .001 in). 3126 Engines: 110.025 0.025 mm (4.3317 .0010 in).
Illustration 9
Magnified view of cross hatch pattern (7) in Illustration 9.
(K) Surface (land) area
(L) Honing scratch or groove.
3. The honed surface must be free of glaze and/or burnish. Refer to the "Glaze" and "Burnish"
sections for additional information.
Page 12 of 15
Illustration 10
Use a dial bore indicator and check the diameter of the bore.
4. During honing, check the size of the bore at several locations along the length of the bore
and also around the circumference.
Illustration 11
Check the bore diameter at locations (M) and (N). Location (M) is 6.4 mm (.25 in) (O) from each end of the sleeve.
5. Inspect the bore dimension at several points that are perpendicular (at right angles) to the
crankshaft centerline. The following three specific locations are primary gauge points, both
during and after honing.
a. Check the diameter at locations (M, Illustration 11), 6.4 mm (.25 in), from each end of the
sleeve.
b. Check the diameter at the center of the sleeve, location (N, Illustration 11).
3. After the honing cycle is completed and before the engine is assembled, remove the
camshaft bearings to permit cleaning of the cylinder block.
Page 13 of 15
Glaze
Glazing produces a brown color on the surface of the cylinder wall.
Glazing can be caused by honing stones that are not cutting correctly or honing stones which are
overheating. Overheating causes the honing oil to oxidize and transfer the residue into the cylinder
wall.
Inspect the tooling to make sure the honing stones are seated correctly in the holders. The honing
stones must also be used with the recommended volume and type of honing oil.
Make sure the recommended Stock Removal Rate, Honing Per 0.03 mm (.001 in) Stock Removal,
and Advance Feed settings are correct for the tooling being used. Refer to Charts A and B.
Burnish
Burnish is when the cylinder walls have a smooth finish or shiny surface, but there are areas of the
bore that have not been honed correctly.
Burnishing can be caused by honing stones that are not in even contact with the cylinder wall.
Inspect to make sure that the honing stones are seated correctly in the holders. Check for even
wear of the honing stones and make sure the tooling is correctly aligned.
Cleaning Procedure
NOTICE
The result of incomplete and/or
insufficient cleaning of the cylinder
block will be piston seizure or rapid wear
of the cylinder sleeve bores, pistons and
piston rings. Only the thorough use of a
rotary brush will correctly remove the
abrasive particles left behind from the
honing procedure.
Use a 1P-5580 Brush Group with a strong detergent and water solution to thoroughly clean the
cylinder block, the main oil gallery and oil supply passage, the camshaft bearing oil passages, and
the cylinder bores.
The cylinder block must be thoroughly cleaned in an agitator-type cleaning tank.
Note: Use the 1U-7429 Brush to clean the honed bore of the cylinder sleeve. Put clean
SAE 30W engine oil on all machined surfaces after the cleaning procedure is
completed.
Keep a protective cover on the cylinder block until final assembly.
Final Assembly
For engine assembly, refer to the specific engine Service Manual for any special procedures and
bolt torques.
Page 14 of 15
Chart E.
Rottler HP3A Honing Machine Data
Semifinish
Rough1
Item
Finish
3114/3116
3126
3114/3116
3126
3114/3116
3126
104.935 0.025
mm
109.935 0.025
mm
104.986 0.025
mm
109.986 0.025
mm
105.025 0.025
mm
110.025
0.025 mm
(4.1313 .0010
in)
(4.3281 .0010
in)
(4.1333 .0010
in)
(4.3302 .0010
in)
(4.1348 .0010
in)
(4.3317
.0010 in)
Standard Bore
Cylinder Length
203.2 mm (8.0 in)
203.2 mm (8.0 in)
203.2 mm (8.0 in)
514-5-61B
514-5-61B
514-5-61B
Stroke Scale
15.9 mm (.625 in)
15.9 mm (.625 in)
15.9 mm (.625 in)
Cylinder Length Setting
203.2 mm (8.0 in)
203.2 mm (8.0 in)
203.2 mm (8.0 in)
Rotation Speed (rpm)
165
165
165
Strokes per Minute
55
55
55
0.0102 mm (.0004 in)

per 2 strokes
0.0102 mm (.0004 in)

per 5 strokes
0.0102 mm (.0004 in)

per 8 strokes
Top Over Stroke
19.05 mm (.750 in)
19.05 mm (.750 in)
19.05 mm (.750 in)
Stone
514-5-54M (80 grit)
514-5-54N (180 grit)
514-5-54Q (320 grit)
100%
80%
40%
0.076 to 0.102 mm
0.051 mm
0.020 mm
(.003 to .004 in)
(.002 in)
(.0008 in)
3 increments
3 increments
2 increments
2.3 to 3.05
(90 to 120)
0.64 to 0.99
(25 to 35)
0.31 to 0.50
(12 to 20)
Hone Head
Feed Rate
Load Meter
Stock Removal Rate
per Minute
Honing per Each
0.03 mm (.001 in)
Stock Removal,
Advance Feed
Surface Finish:
micrometer
(microinch)
Note: Make sure the stress plate is installed prior to any machining procedures on the cylinder sleeve.
1
Rottler recommends boring (cutting) for the cylinder sleeve rough cut, rather than honing. Both methods are acceptable.
Chart F.
Sunnen Honing Machine Data
Item
Rough
Semifinish
Finish
3114/3116
3126
3114/3116
3126
3114/3116
3126
104.935 0.025
mm
109.935 0.025
mm
104.986 0.025
mm
109.986 0.025
mm
105.025 0.025
mm
110.025 0.025
mm
(4.1313 .0010
in)
(4.3281 .0010
in)
(4.1333 .0010
in)
(4.3302 .0010
in)
(4.1348 .0010
in)
(4.3317 .0010
in)
Standard Bore
Cylinder Length
Hone Head
203.2 mm (8.0 in)
203.2 mm (8.0 in)
203.2 mm (8.0 in)
CK - 3000
CK - 3000
CK - 3000
Page 15 of 15
Stroke Scale
69.9 mm (2.75 in)
69.9 mm (2.75 in)
69.9 mm (2.75 in)
Cylinder Length Setting
203.2 mm (8.0 in)
203.2 mm (8.0 in)
203.2 mm (8.0 in)
152 mm (6.0 in)
152 mm (6.0 in)
152 mm (6.0 in)
461
461
461
572
572
572
1551
1551
1551
1702
1702
1702
9.5 mm (.375 in)
9.5 mm (.375 in)
9.5 mm (.375 in)
EHU - 123
EHU - 525
JHU - 625
85%
75%
40%
0.13 mm
(.005 in)
0.064 mm
(.0025 in)
0.051 to 0.064 mm
(.0020 to .0025 in)
0.03 mm (.001 in)
0.08 mm (.003 in)
0.08 mm (.003 in)
0.20 to 0.50
(8 to 20)
Stroke Length
Strokes per Minute
Rotation Speed (rpm)
Feed Rate
Top Over Stroke
Stone
Load Meter
Stock Removal Rate
per Minute
Honing per Each
0.03 mm (.001 in)
Stock Removal,
Advance Feed
Surface Finish:
Micrometer
(microinch)
Note: Make sure the stress plate is installed prior to any machining procedures on the cylinder sleeve.
1
2
For a Sunnen CK-10 Honing Machine.

For a Sunnen CV-616 Honing Machine.
Direitos Autorais 1993 - 2012 Caterpillar Inc.

Todos os Direitos Reservados.
Rede Particular Para Licenciados SIS.
Fri Oct 26 18:03:40 UTC-0300 2012

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Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 and ...

Diretrizes para Reutilizao e Recuperao

Data de Publicao -10/10/2002

Data de Atualizao -10/10/2002

Installing a 7C-6208 Cylinder Sleeve in 3114 and 3116 Engines and

Tooling and Equipment

Rottler Model F2VB

Rottler Model FA2AVB

Sleeve Installation Tools

Hydraulic Puller Group

Tools for Honing Procedure

Stress Plate Group

Cylinder Head Stress Plate

of the following tools are acceptable for use in this procedure.

When replacement parts are required for

Machining Procedure and Specifications

107-7604 Cylinder Sleeve (3126)

Original Cylinder Bore Diameter

Original Cylinder Bore Diameter

109.732 0.013 mm (4.3201 .0005 in)

114.775 0.013 mm (4.5187 .0005 in)

196.77 0.13 mm (7.747 .005 in)

196.85 0.08 mm (7.750 .003)

0.3 mm (.01 in) x 45 degree radius

2.3 mm (.09 in) x 10 degree radius

0.5 mm (.02 in) x 45 degree chamfer

1.5 mm (.06 in) x 45 degree chamfer

Note: Refer to Illustration 1 for item callouts.

Stress Plate Group

Position boring tool on cylinder block.

Installation of Cylinder Sleeve

Maximum height above top

Maximum height above top

Stress Honing Procedure

Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 a...

Position stress plate (1) over cylinder head gasket (4).

Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 a...

Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 a...

Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 a...

Estrutura do Produto - SEBF8261 - Installing a 7C-6208 Cylinder Sleeve in 3114 a...

203.2 mm (8.0 in)

203.2 mm (8.0 in)

203.2 mm (8.0 in)

15.9 mm (.625 in)

15.9 mm (.625 in)

15.9 mm (.625 in)

Cylinder Length Setting

203.2 mm (8.0 in)

203.2 mm (8.0 in)

203.2 mm (8.0 in)

Rotation Speed (rpm)

Strokes per Minute

0.0102 mm (.0004 in)

0.0102 mm (.0004 in)

0.0102 mm (.0004 in)

Top Over Stroke

19.05 mm (.750 in)

19.05 mm (.750 in)

19.05 mm (.750 in)

514-5-54M (80 grit)

514-5-54N (180 grit)

514-5-54Q (320 grit)

(.003 to .004 in)

203.2 mm (8.0 in)