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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

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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. These cast iron cylinder blocks have been damaged by cavitation
erosion.

Refer to "Examples of Erosion" in this Special Instruction for the type of erosion that can be
repaired with this procedure.

Note: Do not perform any procedure in this Special Instruction until you
understand the information.

For questions or additional information concerning this Special Instruction, contact

Caterpillar Service Support Division, Dealer Support (309) 636-5833.

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

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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.

Illustration 1

Pitting has occurred in the cylinder bore (head bolt boss).

Illustration 2

Pitting has occurred in the sidewall of the cylinder block.

Surface Preparation
After all machining or salvage work has been completed the cylinder bore must be
thoroughly cleaned.

Note: The cylinder block must NOT be put in a caustic cleaning solution after
the Belzona® repair material has been applied.

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Illustration 3

Deep pitting has occurred within the cylinder liner bore.

Illustration 4

Pitting is removed with a pneumatic needle scaler.

1. If the eroded area contains deep pitting, all corrosion must be removed from the pitted
area. Refer to Illustration 3. This removal process can be manually performed by
using an ice pick or by using a pneumatic needle scaler. Refer to Illustration 4.
NOTICE

Do NOT apply excessive force against

the thin wall section of a cylinder block.

Excessive force may cause breaks and

cracks in the thin wall.

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Illustration 5

The area has been ground so that the surface appears dull. The feel of the surface is similar to medium grade sandpaper.

2. After the corrosion has been removed, grind the entire repair area. Grind an additional
25.4 mm (1.00 inch) around the outer edge of the damage.

The grinding will provide a rough finish for good adhesion for the repair material.

This grinding can usually be done with an electric grinder and a medium coarse
carbide bit or with a rotary file.

3. Apply light pressure only.

Allow the tool to bounce slightly in order to produce the maximum roughness.

If the section to be repaired has limited clearance with a cylinder liner, remove
additional metal as necessary to permit a slight build-up with the Belzona® repair
material.

Note: Do NOT grind all the way through the cylinder block.

Do NOT remove more than 3.1 mm (0.125 inch) of the base material.

NOTICE

Do NOT permit any power tools to come

in contact with the cylinder liner seat
area. A power tool that comes in contact
with this area will result in an improper
seal around the cylinder liner.
4. After the required finish of the surface has been obtained, clean the area that will be
repaired.

Note: All dirt and oil residue MUST be removed. Use the cleaner/degreaser to
thoroughly clean the area that will be repaired.

NOTICE

Oil base cleaners must NOT be used

because they leave an oily film.

This oily film will prevent the repair

material from adhering to the cylinder
block.
5. Use a clean shop towel in order to check the cleanliness of the area that will be
repaired.

Repeat the cleaning procedure until the area is completely clean.

After the final check for cleanliness has been performed, again apply the cleaner/
degreaser. Allow the cleaner/degreaser to dry without contacting the surface again.

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Note: The finish of the surface and the cleanliness of the surface are essential for a
successful repair.

Application of Repair Material

Mixing The Repair Material

The repair material will not harm the skin

under normal circumstances. To prevent
any possible injury, it is recommended
that rubber gloves be worn. Before
using the repair material, read and make
sure you understand the manufacturer’s
Material Safety Data Sheets enclosed
with the repair material.
1. To make the repair material, use the supplied tools or use a clean putty knife. Mix one
part solidification mixture to three parts (by volume) of the base material.

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.
2. Mix the repair materials only in small amounts. This method allows time for the
application of the repair material before it hardens and becomes difficult to apply.

Note: The time that is required for the repair material to solidify will vary according to
the ambient temperature. The repair procedure that was stated in this Special
Instruction was performed at a temperature of 20°C (68°F). The repair material will
solidify faster at warmer temperatures. The repair material will require additional time
to solidify at cooler temperatures.

The ambient temperature determines the time that is required for the repair material to
solidify. Refer to the "Temperature and Time" chart included with the Belzona repair
material.

3. The repair material should be spread apart. Next, the repair material should be folded
together. Repeat the process of spreading apart and folding together until complete
mixing is achieved. The repair material is completely mixed when a consistent color is
achieved.

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This method is preferred to a method that uses stirring motion.

Note: Do NOT place the repair material in a pile. Repair material that is spread apart
will slow the amount of time that is needed for the repair material to cure.

Note: No more than two cylinder liner bores should be repaired at the same time.
Adherence to this rule should be maintained until additional experience with the
characteristics of the repair material is achieved.

Illustration 6

Repair material is applied into the holes and into the pitted areas.

4. The repairable sections are identified. Next small amounts of the repair material are
applied into any holes or pitted areas.

The repair material is firmly applied in order to remove any air pockets that may have
formed.

Illustration 7

Repair material does not extend beyond the area that has been prepared and cleaned.

5. 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.
When too much repair material is applied, the excess repair material will increase the
grinding time in the finishing procedure.

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Make sure that you taper the edges of the repair material. In this way, the repair
material blends into the surrounding metal.

Do not go beyond this area that has been prepared and cleaned! Any repair material
that mistakenly extends beyond this area must be removed.

When the repair material is being applied, a smooth finish is not necessary.

The procedure "Surface Finishing of the Repaired Area" within this Special Instruction
will provide instructions on the ability to attain the smooth finish.

NOTICE

When repairing an area that has eroded

into an oil gallery, do NOT contaminate
the inside of the oil gallery with excess
repair material.

The repair material will NOT adhere to

an unprepared surface of the base
metal.

Any repair material that is pressed

through a hole and into the oil gallery
MUST be removed.

Surface Finishing the Repaired Area

1. After approximately 30 minutes from the original mixing time, the applied repair
material can be smoothed.

Put on rubber gloves and check the surface of the repair material. The check will
determine the condition of the surface. The surface may look like a dried film. The
surface may also be somewhat sticky.

2. If the repair material sticks to the finger of the glove, the repair material is too wet.

Dip the fingers of your glove in water. Rub the surface of the repair back and forth in
order to get a smooth finish of the repair material at the repaired area.

NOTICE

Use only enough water to wet the glove.

Too much water on the Belzona repair

material can have an adverse effect on
its mechanical strength.
3. Press firmly in order to expel any air that may have been trapped in the repair material
during the smoothing process.

The correct result will reduce the required time to grind once the Belzona repair

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material has cured.

Illustration 8

The finish grind of the repaired area has been performed on the repair material.

4. After the repair material has been applied for two hours, the repair material should be
hard enough for the finish grind.

In those areas that have close clearances, grind away enough material in order to
return the piece back to the original dimensions.

Other areas should be left with a slight buildup of the repair material for resistance to
future erosion.

The cylinder block can now be cleaned with steam in order to remove the debris that
remained after the grinding procedure.

NOTICE

Do NOT place the cylinder block on a

hot caustic tank after this type of repair
has been performed.

Some caustic solutions, at higher

temperatures, can damage the repair
material.
5. After the cleaning procedure is completed, the cylinder block can be assembled.

Note: When the Belzona Ceramic R Metal is correctly mixed and used at a
temperature of 21°C (70°F), the repair material will develop full mechanical
capabilities in 24 hours.

Ordering The Repair Material

The Belzona  Ceramic R Metal must be ordered from one of the Belzona worldwide
distributors. To locate the distribution that is nearest to you, contact one of the following
offices:

North America

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Belzona America, Inc.

America's Gateway Park
2000 N.W. 88 Court
Miami, FL 33172

Telephone: (305) 594-4994

Toll-free: (800) 545-0456

Telex: 645549

Fax: (305) 599-1140

Europe

Belzona Molecular, LTD.

Cairo Road, Harrogate, North Yorkshire
HG1 4AY, England

Telephone: 011 44 (1423) 567641

Telex: 57938

Fax: (01423) 505967

Copyright 1993 - 2006 Caterpillar Inc. Wed Jan 18 11:55:28 UTC+0300 2006
All Rights Reserved.
Private Network For SIS Licensees.

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