Guideline For Reusable Parts And Salvage Operations

Specifications and Salvage for Spacer Plates on 3500 Engines

Media Number -SEBF8226-03 Publication Date -09/07/2002 Date Updated -09/07/2002

   
SEBF82260001

Specifications and Salvage for Spacer Plates on 3500

Engines
SMCS - 1221

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SEBF8226-03
July 2002
SMCS Code: 1221

 GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS

Specifications and Salvage for Spacer

Plates on 3500 Engines
 

Summary of Revisions

Page Description

All Updated information.

Introduction
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) 636-5833.

Summary
Reconditioning a 3500 Engine does not necessarily result in the installation of new
spacer plates as part of the procedure. Spacer plates can often be reused with the
same performance as new ones.

Once the spacer plate is removed from the engine, compare it to the measurements
and type of damage shown in this guideline. If the type of spacer plate wear or damage
encountered is not shown to be reusable in this guideline, do not use the spacer plate
again.

General Information
The 110-6994 Spacer Plate is needed with the 118-9494 Liner that has a larger flange
diameter.

The spacer plate is made of aluminum and therefore requires special handling to
prevent damage.

The 110-6994 Spacer Plate replaced the

9Y-1485 Spacer Plate that replaced the
8N-6864 Spacer Plate. The 118-9494 Liner is replacing the 110-6993 Liner that
replaced the 8N-6861 Liner.

Nomenclature

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Illustration 1

110-6994 Spacer Plate used on 3500 Engines.

Chart A

110-6994 Spacer Plate

Hole Qty. Description

1 2 Dowel Hole

2 4 Large Water Port

3 4 Small Water Port

4 8 Large Bolt Hole

5 1 Oil Supply Hole

6 2 Small Bolt Hole

7 1 Follower Pocket

 
General Procedure
To determine if a spacer plate is reusable, follow these instructions in sequence.

1. Make a visual check of the general condition of the spacer plate, looking for
obvious damage.
2. Clean the spacer plate thoroughly. See "Cleaning" section.
3. After cleaning the spacer plate, visually inspect it again for cracks, corrosion,
erosion, and other damage that is difficult to detect.

Plate Thickness
The thickness of the 110-6994 Spacer Plate is 12.313 ± 0.025 mm (0.4848 ± 0.0010
inch). The minimum thickness is 12.288 mm (0.4838 inch).

Initial Inspection
Before cleaning the spacer plate, make a quick visual inspection for bending, scratches,
deep cuts, heat, and impact damage. Do not reuse any spacer plate that has:

 Cracks with spalling of material.

 Scorch paths, from exhaust gas leakage, with measurable width and depth in any area.

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Illustration 2

Bent or warped spacer plate.

Do not use again

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Illustration 3

Impact damage to edge of spacer plate which affects spacer plate thickness, and oil sealing capability.

Do not use again

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Illustration 4

Deep cut (8) between large bolt hole (4) and cylinder liner clearance hole.

Do not use again

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Illustration 5

Deep cut (9) around large water port (2).

Do not use again

Cleaning
3500 Engines use a die cast aluminum spacer plate, which weighs and costs less than
steel spacer plates. The aluminum spacer plate requires more care during handling and
cleaning to prevent damage and retain reusability. Recommended cleaning materials
are Xylene solvent and/or glass bead blasting.

When cleaning aluminum plates:

1. Use only glass beads. Do not use aluminum oxide or any other abrasive. Do not
mix anything with glass beads.
2. Do not use wire brush or wire wheel.
3. Scraping and sanding should be avoided.
4. Do not use Scotch Brite® scouring pads to clean spacer plates.

Xylene solvent or brake fluid can be used to clean PtFE Teflon© residue from spacer
plates. Glass beads should be used with certain precautions to clean aluminum plates
(glass beads tend to alter plate dimensions and can hide cracks normally seen during
visual inspection).

Note: Never use glass beads larger than 230 µm (0.0091 inch) to clean
the spacer plate.

For the best cleaning results use size 10 glass beads, 88 to 149 µm (0.0035 to 0.0059
inch), with 550 to 620 kPa (80 to 90 psi) air pressure. Change the glass beads and
check nozzle regularly for best results.

Visual Inspection (Unacceptable Cracks and/or Depressions)

After cleaning, check for cracks and connecting surface depressions due to corrosion,
erosion, and handling damage in the following areas (both sides of the plate).

1. Within 6.0 mm (0.24 inch) along the edge of the plate and valve mechanism
opening.
2. Within 6.5 mm (0.26 inch) along the edge of the gasket (or where gasket goes on
plate).
3. Inside and 6.0 mm (0.24 inch) around oil supply hole (5).
4. Within 6.0 mm (0.24 inch) around small and large water ports (2 and 3).

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Illustration 6

Deep scratch (10) and damage (11) around oil supply hole (5).

Do not use again -

If either type of damage is present in any of the four areas specified in "Visual Inspection (Unacceptable Cracks and/or Depressions)"
section.

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Illustration 7

Maximum allowable amount of erosion. Arrow points out erosion around water port.

Use again

Note: Do not use a spacer plate that has a greater amount of erosion on
any of the four areas mentioned in "Visual Inspection (Unacceptable
Cracks and/or Depressions)".

Areas outside of these boundaries may have surface depressions up to 1.0 mm (0.04
inch) deep and 6.0 mm (0.24 inch) in diameter. This applies to both sides of the plate.

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Illustration 8

Depressions (12) around small bolt hole (6) and depressions (13) along dege.

Use again -
If depressions (12) are the only damage present and are less than 1.0 mm (0.04 inch) deep. Take measurements after the raised areas are
removed with a file.

Do not use again -

If depressions (13) are present. No depressions are allowed within 6.0 mm (0.24 inch) along the
edge of the spacer plate.

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Illustration 9

Arrow points to crack without measurable width (hairline).

Do not use again

Precautions When Measuring Liner Projection

Do not use steel washers or excessive torque to hold down the spacer plate while
taking projection measurements. Instead, use brass and fibrous washers under bolt
heads. Also use correct torques to prevent damage to spacer plates.
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