SEBF8301-29 Inspection and Reuse of Critical Fasteners Used in All Engines

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Reuse And Salvage Guidelines

Inspection and Reuse of Critical Fasteners Used in All Engines{7553, 7553}
Media Number -SEBF8301-29 Publication Date -06/06/2014 Date Updated -06/06/2014
Caterpillar: Confidential Yellow
i05821072
Inspection and Reuse of Critical Fasteners Used in All

Engines{7553, 7553}
SMCS - 7553-040
Engine: 3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All All 3500 Engines All
3600 Engines All C280 C-10 All C-9 and C9 All C11 All C12 and C-12 All C13 and C-13 All
C15 and C-15 All C16 and C-16 All C175 Engines C18 and C-18 All C27 All C32 All C4.4
Engines C6.6 C7 All C7.1
Introduction
Table 1
Revision Summary of Changes in SEBF8301
29 Added section ""Reusability for Critical Fasteners in C-Series Engines" "
28 Added new serial number prefixes.
27 Updated Reuse for C175 Damper Bolts
Updated Illustrations 8, 9, and 10 from black and white to color.
26
Added Illustration 12
25 Added new serial number prefixes.
Added footnote on mag particle inspecting C175 head bolts.
24
Added new serial number prefixes.
23
Updated 3500 Head Bolt guidance in Tables 3 and 4.
22 u060lc2
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© 2014 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law. Information contained in this document is considered
Caterpillar: Confidential Yellow.
This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to
establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers
and customers to benefit from cost reductions. Every effort has been made in order to provide the
most current information that is known to Caterpillar. Continuing improvement and advancement
of product design might have caused changes to your product which are not included in this
publication. This Reuse and Salvage Guideline must be used with the latest technical information
that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for feedback in
the Service Information System. In order to address an urgent issue, use the following resources in
order to communicate your request to Caterpillar Repair Process Engineering:
• Caterpillar Dealer Technical Communicator
• Dealer Solution Network
• Caterpillar Technical Representative
• Knowledge Network
Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS
for information about canceled part numbers and replaced part numbers. NPR will provide the
current part numbers for replaced parts.
Important Safety Information
Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by u060lc2
recognizing potentially hazardous situations before an accident occurs.Caterpillar:
A person must be alertYellow
Confidential to
potential hazards. This person should also have the necessary training, skills, and tools in order to
perform these functions properly. Safety precautions and warnings are provided in this instruction
and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to
you or to other persons. Caterpillar cannot anticipate every possible circumstance that might
involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on
the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that
is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and
for other people to use. You should ensure that the product will not be damaged or the product
will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that
are used.
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on

this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the safety alert symbol which is followed by a signal word such as
danger, warning, or caution. The "WARNING" safety alert symbol is shown below.
This safety alert symbol means:
Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and
in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The safety information in this document and the safety information on the machine
are not all inclusive. You must determine that the tools, procedures, work methods, andu060lc2
Caterpillar:
operating techniques are safe. You must determine that the operation, Confidential Yellow
lubrication,
maintenance, and repair procedures will not damage the machine. Also, you must determine
that the operation, lubrication, maintenance, and repair procedures will not make the
machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on
information which was available at the time of publication. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete, most current information
before you start any job. Caterpillar dealers can supply the most current information.
Summary
Engine reconditioning does not necessarily result in the installation of new bolts as part of the
reconditioning procedure. Bolts can often be reused with the same performance as new ones until
the next overhaul. This guideline covers cylinder head, main bearing, connecting rod,
counterweight, and flywheel bolts.
Compare the bolts that are shown in this guideline and the bolts removed from the engine to be
reconditioned. In some cases, the bolt will not be reusable.
Never install a bolt this guideline shows cannot be used again. If a bolt has wear or damage that is
not shown in this guideline, do not reuse the bolt again.
References
Reference Service Literature, SEBV0545, "Thread Fasteners Applied Failure Analysis"
Reference Reuse and Salvage Guidelines, SEBF8063, "Visual Inspection of Connecting Rods"
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.
Nomenclature
Regular Bolts
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Bolt nomenclature
(1) Head
(2) Washer face
(3) Under head fillet
(4) Shank
(5) Threads
Three highest stress areas on a bolt
Patch Lock Bolts

Patch lock bolts are identified by the nylon patch thread adhesive applied to one side of the bolt,
as shown in Illustration 5. Patch lock bolts are desirable for use in some vibratory applications
because of the locking (adhesive) compound. This compound absorbs the vibrations without
breaking, maintains the applied torque of the bolt, and can be reused. It is recommended, after the
third removal, to install a new nylon patch lock bolt.
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Patch lock bolt
Adhesive Lock Bolts
NOTICE
Reusing adhesive lock bolts could cause the bolt to loosen, resulting in
component damage.
The bolts that have a pre-applied thread adhesive with 360 degree coverage are not reusable. Refer
Illustration 6. Reapplying the adhesive locking compound to the bolt is difficult to do accurately.
However, the discarded bolts may be cleaned and reused in another application requiring a
different locking compound.
Adhesive lock bolt u060lc2

(A) No adhesive present on 2 ± 1 threads
(B) Adhesive should be on 6 ± 2 threads
Reduced-Diameter Shank Bolts

Bolts with a reduced diameter shrank are special bolts designed to stretch more than a standard
bolt in order to provide increased clamping force to a bolted joint. Reduced-diameter shank bolts
are identified by a smaller diameter length between the head and the threaded end of the bolt. The
length has a diameter less than the outside diameter of the threads. The area of reduced diameter is
straight length rather than a tapered length as with a bolt that has experienced "necking".
Reduced-diameter-shank bolt
(C) Length of smaller diameter shank
Inspection
Use the following steps in order to perform the inspection for the bolt.
1. The head (1)
a. Inspect for corrosion and pitting. Corrosion and pitting is allowable as long as the
pitting does not interfere with the socket or wrench.
b. Check for any cracking, chipping, or rounding of the corners. If this type of damage is
present, do not reuse the bolt.
2. The under head fillet (3)
a. Inspect for smoothness. The presence of wear indicated by a shiny line that has not
raised any material does not cause a stress riser. The shiny line does not make the bolt
unusable. If there are signs of corrosion, cracks, nicks, pits, or gouges, do not reuse
the bolt.
3. The bolt washer face (2) u060lc2

a. Inspect for corrosion, burrs, and any other conditions that would cause stress risers.
b. Inspect for flatness, making sure the bolt washer face properly seats against the joint
surface.
c. Inspect for corrosion or burrs that would not allow the bolt washer face to seat
properly. If either condition is found, do not reuse the bolt.
4. The shank (4)
a. Inspect for straightness. If there are signs of bending, necking, wear, corrosion,
pitting, or cracks on the shank, do not reuse the bolt.
5. The bolt threads (5)
a. Inspect for necking, corrosion, cracking, deforming, stripping, or any other physical
damage. If this type of damage is present, do not reuse the bolt.
6. Check the nylon patch on patch lock bolts. These bolts should only be used three times
before replacement.
7. If the bolt is an adhesive lock bolt, replace with a new unused bolt.
Necking
Bolts may show signs of necking, which can be caused by severe overloading. Do not use a bolt
showing signs of necking.
Overloaded and plastically deformed (necked) bolt
Do not use again
Fretting and Fretting Corrosion

Fretting and fretting corrosion indicate joint movement. Fretting indicators are polishing and
denting of surfaces.
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Fretting on a con-rod washer face
Do not use again
Fretting corrosion indicators are microwelding, metal transfer, and reddish oxide formation.
Fretting corrosion is present at the mid-shank of this bolt. Note the reddish oxide deposit.
Do not use again
Corrosion
Corrosion occurs on bolts when there is a chemical reaction that eats away at the bolt. Corrosion
leads to pitting which can cause a fatigue fracture in the bolt. Corrosion will give the surface of
the bolt a rough, porous texture.
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Bolts with pitting and a rough, porous texture on the shank of the bolt.
Do not use again
Note: Pitting can cause bolts to crack.
This bolt has suffered a fracture due to corrosion near the head of the bolt. Carefully inspect all bolts for corrosion.
Bolt Cleaning Method

One way to damage a bolt at overhaul is to clean the bolt improperly. If a bolt needs more than
wiping off, clean the bolt in a mild petroleum-based solvent. Make sure that the solvent has not
been contaminated with water. If contaminated, the solvent and water mixture will pit the bolt.
Also, never clean a bolt with a chlorinated solvent. The chlorine will attack the bolt surface and
leave pits. A pitted bolt will fail at low hours. The recommended solution for cleaning any
Caterpillar bolt is to use Hydrosolv 100 heavy-duty cleaner. Nylon patch lock bolts can also be
cleaned using the following method. Adhesive lock bolts can be cleaned, but should not be reused
in an application requiring an adhesive lock bolt.
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Hydrosolv 100 can be used at concentrations from 1 to 30 percent and temperatures from room
temperature up to 93 °C (200 °F). Most tanks and washers run at around 10 to 15 percent
concentration and 88 °C (190 °F). The concentration percentage is determined by the amount of
grease and other materials to be removed from the bolt. Constant agitation of the bolts while
immersed in the tank is recommended.
Reusability for Critical Fasteners in C - Series Engines

Table 2
Critical Fasteners Reusability for C-series Engines (C7.2 through C32)
Fastener Type Reusability of Fasteners
Head Bolts Reuse at any rebuild if reuse criteria is met.
Connecting Rod Bolts Standard bolts can be reused at any rebuild if reuse criteria is met. (1) (2)
Reuse at any rebuild if reuse criteria is met. (Including C27/C32 side

Main Bolts
main bolts)
Flywheel Bolts Reuse at any rebuild if reuse criteria is met.
Dampers Reuse at any rebuild if reuse criteria is met.
(1)
Fractured split rods utilize torque to yield bolts and therefore those bolts must be replaced anytime the joint is
disturbed.
(2)
Machined connecting rods utilize standard bolts.
3500 Family Engine Bolt Reuse and Assembly Lube Type

Table 3
Connecting Rod Bolts (Molykote)
Life First Second Third Rebuild Fourth Fifth Rebuild
Rebuild Rebuild Rebuild
New Reuse bolts Replace with Reuse bolts from Replace with Reuse bolts from
from new new bolts second rebuild new bolts fourth rebuild
Head Bolts (Engine Oil)
Can be reused a maximum of five standard rebuilds as long as reuse criteria is met.
Main Bearing Cap Bolts (Engine Oil)
Reuse at any rebuild if reuse criteria is met
Crankshaft Counterweight Bolts (Molykote)
DO NOT REUSE. Replace with new bolts whenever counterweight segments are removed
Table 4
3524 Coupling to Flywheel Bolts (Engine Oil) (1) u060lc2
Life First Second Fourth

Third Rebuild Fifth Rebuild
Reuse bolts
New Reuse bolts Replace with Reuse bolts from Replace with
from 4th rebuild
from new new bolts 2ndrebuild new bolts
3524 Front / Rear Flywheel Bolts (Molykote)

NEVER REUSE! Replace with new bolts whenever the flywheels are removed
3524 Damper Bolts (Engine Oil)
Reuse bolts
from fourth
from new new bolts second rebuild new bolts
rebuild
Connecting Rod Bolts (Molykote)
Reuse bolts
from fourth
from new new bolts second rebuild new bolts
rebuild
Head Bolts (Engine Oil)
Can be reused a maximum of five standard rebuilds as long as reuse criteria is met.
Main Bearing Cap Bolts (Engine Oil)
Reuse at any rebuild if reuse criteria is met
Crankshaft Counterweight Bolts (Molykote)
DO NOT REUSE. Replace with new bolts whenever counterweight segments are removed
(1)
This reuse criteria applies only to the 231-7068 Bolt . DO NOT REUSE the former 5D-9514 Bolt .
C175 Engine Fasteners

Table 5
Reusable
Fastener Number of times reused
Head Bolts Y Reuse at any rebuild if reuse criteria is met (1)

Rod Bolts
2 (3)
290-2541 (2) Y A visual inspection must be performed at every reuse.u060lc2
Can be reused until overhaul. A visual inspection must be

performed at every reuse.
428-7386 Y
If the bolt has been torqued four times, then a magnetic
particle inspection must be completed. (4)
Quill Tube Bolts N N/A
Injector Hold Down
Y Reuse at any rebuild if reuse criteria is met
Bolt
Tie Bolt for Mains Y 5
Main Stud Y 10
Main Stud Nut Y 10
Rocker Shaft Hold
Y Reuse at any rebuild if reuse criteria is met
Down Bolts
Flywheel Bolts N N/A
Damper Bolts Y Reuse at any rebuild if reuse criteria is met
(1)
The cylinder head bolts must be inspected for cracks and wear during each rebuild. This inspection must include
magnetic particle inspection. The fillet radius should be inspected along with other critical areas.
(2)
Canceled and replaced by 428-7386 Bolt As effective May 2013.
(3)
C175 Rod bolts can be used twice in a running engine. The bolts can be torqued multiple times during assembly
as long as the engine does not run under load. Once the engine has run, then the 2x reuse criteria in this table
must apply.
(4)
Refer to: Reuse And Salvage Guidelines, SEBF8148, "General Salvage and Reconditioning Techniques"for
further information regarding Magnetic Particle Inspection.
Note: Never reuse flywheel bolts.
3600 and C280 Engine Fasteners

Use the following guidelines in order to determine the serviceability of the fasteners:
Thoroughly inspect the fasteners before you reuse any fastener. Do not reuse a fastener that has
any damage. Do not reuse a fastener that has any of these defects:
• Rust
• Nicks
• Thread damage
• Cracks
• Pits
• Deformation
If the fasteners appear to be free of defects, also follow these guidelines: u060lc2
• Replace any stud for the cylinder head after the stud has been tensioned 20 times. This
criteria includes the 1W-2363 Taperlock Stud , 7E-8400 Taperlock Stud , and 187-0450
Taperlock Stud .
• Also replace any stud for the main bearing cap ( 1W-0121 Taperlock Stud ) after the stud
has been tensioned 20 times.
• The cross tie bolt for the main bearing cap ( 3S-7079 Bolt ) can only be tensioned five
times.
• The connecting rod bolt ( 1W-0098 Bolt , 366-5099 Bolt , or 369-7181 Bolt As ) can only
be tensioned five times. Inspect the connecting rod bolt during each inspection of the
bearing for the connecting rod. There must be no fretting of the shank of the bolt. This
includes the knurled area of the bolt. Ensure that the bolt meets the guidelines for reusable
parts. Do not reuse a connecting rod bolt if dimension (X) is greater than 329 mm (12.953
inch). Refer to Illustration 13.
• Do not reuse the nut for a connecting rod bolt. This includes the 6V-9801 12-Point Nut and
205-0640 Nut .
NOTICE
The connecting rod bolt 355-4969 Bolt cannot be reused. The 355-4969
Bolt must be replaced using the latest NPR connecting rod bolt.
(X) Dimension
Copyright 1993 - 2014 Caterpillar Inc. Tue Jun 10 10:57:18 UTC-0300 2014
All Rights Reserved. u060lc2
Private Network For SIS Licensees.
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Reuse And Salvage Guidelines

Inspection and Reuse of Critical Fasteners Used in All

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this product

Do not operate or perform any lubrication, maintenance or repair on

This safety alert symbol means:

Your safety is involved.

When replacement parts are required for this product Caterpillar

Failure to heed this warning can lead to premature failures, product

(2) Washer face

(3) Under head fillet

Three highest stress areas on a bolt

Patch Lock Bolts

Patch lock bolt

Adhesive Lock Bolts

Adhesive lock bolt u060lc2

(B) Adhesive should be on 6 ± 2 threads

Reduced-Diameter Shank Bolts

(C) Length of smaller diameter shank

1. The head (1)

2. The under head fillet (3)

3. The bolt washer face (2) u060lc2

4. The shank (4)

5. The bolt threads (5)

Overloaded and plastically deformed (necked) bolt

Do not use again

Fretting and Fretting Corrosion

Fretting on a con-rod washer face

Do not use again

Do not use again

Do not use again

Note: Pitting can cause bolts to crack.

Bolt Cleaning Method

Reusability for Critical Fasteners in C - Series Engines

Reuse at any rebuild if reuse criteria is met. (Including C27/C32 side

3500 Family Engine Bolt Reuse and Assembly Lube Type

Life First Second Fourth

3524 Front / Rear Flywheel Bolts (Molykote)

C175 Engine Fasteners

Head Bolts Y Reuse at any rebuild if reuse criteria is met (1)

Can be reused until overhaul. A visual inspection must be

Note: Never reuse flywheel bolts.

3600 and C280 Engine Fasteners

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