Inspection and Reuse of Critical Fasteners Used in All Engines

1/30/24, 3:24 PM SIS 2.
Inspection and Reuse of Critical Fasteners Used in All Engines {1000, 7553, 7553} (SEBF8301-49)
SMCS - 1000, 7553 i09902745

Caterpillar Products
All Cat Engines
PIP
Revision History:
Table 1
-
202 1046
4
12: 01/3 666
Revision Summary of Changes in SEBF8301
/ 4
2
Updated the "3600 and C280 Engine Fasteners" Section.
SEB 4:49+ 0
49 Added a reference to Engine News, "A New Torque Procedure for Connecting Rod Bolts Is
Now Used on 3600, G3600, and C280 Engines" to Table 2.
© 2 F830 03:00
48 Added note to Table 4
47 Updated the "Inspection" Section.
46
42–45
0 2 1
Updated Table 4 to indicate that 1N-3825 is torque to yield and should not be reused.
Cat 4 C
Added new serial number prefixes for New Product Introduction (NPI).
41
e r
Con illa terpi
and must not be reused. p a
Changed Table 4 to indicate that C-10 and C-12 engines have torque to yield head bolts
fide r: llar
Added new serial number prefixes for New Product Introduction (NPI).
Introduction ntia Inc

l Ye .
© 2023 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized
llow
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 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 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).
Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair
options or modifications to reuse and salvage techniques and/or methods.
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for
feedback in the Service Information System (SIS web) interface.
https://sis2.cat.com/#/print-preview/service/4a06006c-66b8-4570-a10c-ac914b923d1a 1/30
1/30/24, 3:24 PM SIS 2.0
Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part
Record (NPR) on the Service Information System website 2.0 (SIS web 2.0) 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 recognizing
potentially hazardous situations before an accident occurs. A person must be alert to potential hazards.
This person should also have the necessary training, skills, and tools 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. Ensure that the product will
not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that
are used. Ensure that the product will not be damaged or made unsafe by any operation, lubrication,
maintenance, or the repair procedures 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.
1/30/24, 3:24 PM SIS 2.0
The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2 for an example of a “WARNING” Safety
Alert Symbol.
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. Determine that the tools, procedures, work methods, and operating techniques are
safe. Determine that the operation, lubrication, maintenance, and repair procedures will not
damage the machine. Also, 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
This guideline provides the procedures necessary to determine the reusability of critical engine fasteners.
Life will vary depending on application, load, lubrication, and environment.
This guideline contains the latest standards of engineering, which will help minimize owning and
operating costs. Parts are expected to reach the next Planned Component Rebuild (PCR) if the parts
meet the specifications within this guideline and are intended for similar applications. Use this guideline
to determine whether a part should be reused. Do not install a part that is not reusable. During
reconditioning, correct any condition that might have caused the original failure.
1/30/24, 3:24 PM SIS 2.0
The dimensions and tolerances provided are to return a part / component to specification. The
dimensional information alone is not solely used to condemn a part from reuse.
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. Sometimes, 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
Note: Refer to the appropriate Remove and Install (R&I), Disassembly and Assembly (D&A), and
Operation and Maintenance Manual (OMM) for the part or machine of focus before initiating this
inspection or procedure.
Table 2
References
Media
Publication Type & Title
Number
"C175 Rod Bolts"
Channel1 English
https://channel1.mediaspace.kaltura.com/media/1_af4iwqml
"C175 Rod Bolts_SP"
Channel1 Spanish
https://channel1.mediaspace.kaltura.com/media/+C175+Rod+Bolts_SP/1_d65z6mds
"C175 Rod Bolts_PORT"
Channel1 Portuguese
https://channel1.mediaspace.kaltura.com/media/C175+Rod+Bolts_PORT/1_bgp6v64x
"Why Reuse and Salvage Parts"
Channel1
https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
KENR6052
Disassembly and Assembly, "Pistons, Liners, and Connecting Rods - Install"
SEBD9973 Engine News, "A New Torque Procedure for Connecting Rod Bolts Is Now Used on 3600,
G3600, and C280 Engines"
1/30/24, 3:24 PM SIS 2.0
SEBD9992 Engine News, "A New Torque Procedure for Connecting Rod Bolts Is Now Used on 3600,
G3600, and C280 Engines"
SEBV0545 Service Literature, "Thread Fasteners Applied Failure Analysis"
SEBF8064
Reuse and Salvage Guidelines, "Reuse and Salvage for Connecting Rods"
SEBF8187
Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures"
Service Advisories, Service Letters, and Technical Service

Bulletins
NOTICE
The most recent Service Advisories, Service Letters, and
Technical Service Bulletins that are related to this component
should be reviewed before beginning work. Often Service
Advisories, Service Letters, and Technical Service Bulletins
contain upgrades in repair procedures, parts, and safety
information which pertain to the components being repaired.
Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform
every task within this document. Tooling needs may vary for the scope of work to be performed for each
specific rebuild.
Table 3
Required Tooling and Equipment
Part Number Description

— (1) Personal Protective Equipment (PPE)
9U-6070 Heat Gun (110V)
9U-6072 Heat Gun (220V)
607-8035 Wiper
546-5747 Seal Kit
455-8106 Rod Bolt Gauge
486-1524 Kyntex HD Cabinet and Spray Cleaner
— Loctite ® LB 8012Moly Paste
431-4150 Micrometer
1/30/24, 3:24 PM SIS 2.0
(1) Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part
numbers suitable by geographic location and local safety standards.
Replacement Parts
Consult the applicable Parts Identification manual for your engine.
Measurement Requirements
NOTICE
Precise measurements shall be made when the
component and measurement equipment are at 20 °C
(68 °F). Measurements shall be made after both the
component and measurement equipment have had
sufficient time to soak at 20 °C (68 °F). This will ensure
that both the surface and core of the material is at the
same temperature.
Nomenclature
Regular Bolts
Bolt nomenclature
(1) Head
(2) Washer Face
(3) Under Head Fillet
(4) Shank
(5) Threads
1/30/24, 3:24 PM SIS 2.0
Three highest stress areas on a bolt
Inspection
Note: Bolts showing handling damage (dings, dents, nicks, scratches, and so on) within any area of the
bolt must be replaced with new. This does not include where the head will engage with the socket.
Use the following steps 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. Check the underhead fillet radius for nicks. The radius shall be smooth an even around the full
diameter of the bolt. If a circular nick is present in the fillet radius, then DO NOT USE AGAIN.
Bolts should be used with a washer with enough internal clearance not to interfere with the fillet
radius. If a washer is not used, the hole the bolt head surface mates to should have an internal
chamfer to accommodate the fillet radius. A circular nick, scratch, or crack in the fillet radius will
act as a stress riser reducing the fatigue life of the bolt. If a circular nick, scratch, or crack is
present in the fillet radius, then DO NOT USE AGAIN.
3. The bolt washer face (2)
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.
1/30/24, 3:24 PM SIS 2.0
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.
1/30/24, 3:24 PM SIS 2.0
PIP
202 -1046
12: 4 / 0 4 666
2 1 / 3
Illustration 6 SEB :49+ 0
4 g03430435
© 2 F830 03:00
Fretting on a con-rod washer face
Do not use again
Cat 024 C 1
Fretting corrosion indicators are microwelding, metal transfer, and reddish oxide formation.
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Con illa terpi
p a
fide r: llar
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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.
1/30/24, 3:24 PM SIS 2.0
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.
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 10. 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.
1/30/24, 3:24 PM SIS 2.0
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 to
Illustration11. 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
(A) No adhesive should be present on the bottom 2 ± 1 threads
(B) Adhesive should be on 6 ± 2 threads beginning 2 ± 1 threads from the bottom
Reduced-Diameter Shank Bolts

Bolts with a reduced diameter shank are special bolts designed to stretch more than a standard bolt to
provide increased clamping force to a bolted joint. Reduced-diameter shank bolts are identified by a
1/30/24, 3:24 PM SIS 2.0
smaller diameter 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
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. 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.
Kynetx HD cleaner 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 4
Critical Fasteners Reusability for C-series Engines (C7.2 through C32)
Fastener Type Reusability of Fasteners

Reuse at any rebuild if reuse criteria is met.(1)
Head Bolts C-10 and C-12 engines have torque to yield head bolts and must not be
reused.
Connecting Rod
Standard bolts can be reused at any rebuild if reuse criteria is met.(2) (3)
Bolts
1/30/24, 3:24 PM SIS 2.0
Main Bolts Reuse at any rebuild if reuse criteria is met.

Flywheel Bolts Reuse at any rebuild if reuse criteria is met.(4)
Dampers Reuse at any rebuild if reuse criteria is met.(5)
(1) Replace cylinder head bolts if engine has experienced a cylinder head to cylinder block joint failure.
(2) Fractured split rods utilize torque to yield bolts and therefore those bolts must be replaced anytime the joint is disturbed.
(3) Machined connecting rods utilize standard bolts.
(4) 1N-3825 is torque to yield and should not be reused. Must be replaced.
(5) 6V-4249, 8T-4182, 7X-2543 and 8T-6408 used on C9.3 Marine Engines with torque turn process is torque to yield and should
not be reused. Must be replaced.
NOTICE
The side main bolts for C27 and C32engines need to be
replaced at rebuild.
3500 Family Engine Bolt Reuse and Assembly Lube Type

Table 5
Connecting Rod Bolts use Loctite ® LB 8012Moly Paste
First Second Fourth

Life Third Rebuild Fifth Rebuild
Rebuild Rebuild Rebuild
Reuse bolts Replace with Reuse bolts from Replace with Reuse bolts from
New
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 use Loctite ® LB 8012Moly Paste
DO NOT REUSE. Replace with new bolts whenever counterweight segments are removed
Table 6
3524 Coupling to Flywheel Bolts (Engine Oil) (1)
Second Fourth
Life First Rebuild Third Rebuild Fifth Rebuild
Rebuild Rebuild
New
from new new bolts 2ndrebuild new bolts 4th rebuild
3524 Front / Rear Flywheel Bolts use Loctite ® LB 8012Moly Paste
NEVER REUSE! Replace with new bolts whenever the flywheels are removed
3524 Damper Bolts (Engine Oil)
Life First Rebuild Second Third Rebuild Fourth Fifth Rebuild
1/30/24, 3:24 PM SIS 2.0
Rebuild Rebuild
New
Connecting Rod Bolts use Loctite ® LB 8012Moly Paste
Second Fourth
Life First Rebuild Third Rebuild Fifth Rebuild
Rebuild Rebuild
New
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 use Loctite ® LB 8012Moly Paste
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 7
Fastener Reusable Number of times reused

Head Bolts Y Reuse at any rebuild if reuse criteria is met (1)
Rod Bolts
Can be reused once if rod is disassembled before overhaul.(3)
290-2541 (2)
Y The inspection procedure documented below must be
followed.
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)
DO NOT REUSE. Replace with new bolts whenever
Crankshaft Bolts N
counterweight segments are removed
Quill Tube Bolts N N/A
HP Fuel Rail 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 Tighten 10 Times
Main Stud Nut Y Tighten 10 Times
Rocker Shaft Hold
Y Reuse at any rebuild if reuse criteria is met
Down Bolts
1/30/24, 3:24 PM SIS 2.0
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 reused once 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 1x 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.
C175 High-Pressure Fuel Rail Bolts
High-Pressure Fuel Rail Bolts are single use only. DO NOT REUSE (1).
(1) HP Fuel Rail Bolts
Visual Inspection of C175 428-7386 Bolt

The 428-7386 Bolt As replaces the 290-2541 Bolt. The current connecting rod bolts have elastomer rings
bonded to the shank of the bolts. The elastomer rings reduce bolt vibration and fatigue during engine
operation.
The connecting rod bolt can be reused if rod is disassembled before overhaul if the bolt passes a visual
inspection and elastomer measurement inspection.
Reference: Refer to Disassembly and Assembly, KENR6052 , "Pistons, Liners, and Connecting Rods -
Install" for instructions on installing the connecting rod bolts.
Reference: To provide addition clarification and details, a Caterpillar Channel 1 video has been created
outlining the critical steps installing C175 Connecting Rod Bolts. Reviewing the video is recommended
prior to starting the process.
Note: A CWS login is required to access Caterpillar Channel 1 Videos.
Table 8
1/30/24, 3:24 PM SIS 2.0
Caterpillar Channel 1
""C175 Rod Bolts"
Title:
English
Caterpillar Channel 1 URL: https://channel1.mediaspace.kaltura.com/media/1_af4iwqml
Table 9
""C175 Rod Bolts_SP"
Title:
Spanish
Caterpillar
Channel 1 https://channel1.mediaspace.kaltura.com/media/+C175+Rod+Bolts_SP/1_d65z6mds
URL:
Table 10
""C175 Rod Bolts_PORT"
Title:
Portuguese
Caterpillar
Channel 1 https://channel1.mediaspace.kaltura.com/media/C175+Rod+Bolts_PORT/1_bgp6v64x
URL:
Reference: Reuse And Salvage Guidelines, SEBF8187 , "Standardized Parts Marking Procedures"
Nomenclature
(1) Head
(2) Shank
1/30/24, 3:24 PM SIS 2.0
(3) Elastomer
(4) Threads
PIP
Cleaning -
202 1046
4
12: 01/3 666 4
Prior to a visual inspection or the taking of measurements the C175 rod bolt must be cleaned of all
/
Molylube. Most cleaning can be accomplished with a clean shop towel. A shop towel will remove
2
SEB 4:49+ 0
Molylube from the elastomer peaks, and leave minimal residue in the valleys. This cleaning method is
typically sufficient for visual inspection and the taking of reuse measurements.
© 2 F830 03:00
If the use of a solvent is required, then soaking or prolonged use must be avoided. Only mineral spirits is
an acceptable solvent to clean the C175 Rod Bolt. Ensure that all safety precautions are obeyed when
0
using hazardous chemicals.
Cat 4 C 2 1
e
Do not use any other common shop solvents including the parts washer, aerosol brake cleaner, and
C
carburetor cleaner.
rpil aterp
Visual Inspection on l
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Use Again
(A) Elastomer flash at ends.
(B) Scuffing or abrasion of outer rib. No rolling, skiving, or cutting observed.
1/30/24, 3:24 PM SIS 2.0
Use Again
(C) Skiving at top of rib. Peeled portion is fully attached on one side, and no tail is observed. Only one occurrence at 5 mm
(0.197 inch) long maximum allowed for reuse.
(D) Elastomer flash axially on both sides of bolt.
Use Again
(E) Abrasion or skiving of elastomer from rolling of material. No loose material observed.
(F) Skiving of material at outer diameter and rolling of material observed. No more than one occurrence 5 mm (0.197 inch) long
maximum allowed for reuse.
1/30/24, 3:24 PM SIS 2.0
Use Again
(G) Skived or cut elastomer. Flap of material is remaining. No more than one occurrence 5 mm (0.197 inch) long maximum
allowed for reuse.
Do Not Use Again
(H) Tip of elastomer rib peeling and rolling into a valley.
1/30/24, 3:24 PM SIS 2.0
Do Not Use Again
(I) Rib detached from elastomer sleeve. Rolling of elastomer.
Do Not Use Again
(J) Rib rolled into adjacent valley.
(K) Rib torn.
Elastomer Measurement
Measurement of the elastomer sleeve diameter must be performed for reuse acceptability based on the
permanent compression of the elastomer material.
To take the measurements, use a 455-8106 Gauge-Block to determine if the rod bolt has enough
elastomer material for another life. The gauge block is machined to the minimum reuse specification of
the elastomer material.
1/30/24, 3:24 PM SIS 2.0
If the rod bolt slides into the gauge block, then the rod bolt is too small in diameter for reuse. It is not
necessary for the rod bolt to slide to the bottom of the gauge block. If the maximum outer diameter of the
elastomer material slides past the gauge block chamfer and into the gauge block groove, then the rod
bolt should not be reused.
The use of the gauge block allows the outside diameter of the elastomer material to be checked
accurately and efficiently. It is important to measure the diameter without any additional pressure on the
elastomer material. Calipers and micrometers have proven to be inaccurate in measuring the elastomer
material.
The rod bolt will need to be placed into the gauge-block and under its own weight inspected for reuse.
The instructions for this test are as follows.
1. Clean the Gauge-Block with a lint free towel and solvent.
2. Apply a film of clean engine oil onto the chamfers of the Gauge-Block. This film of oil will reduce the
friction between the elastomer material and the gauge block providing a more accurate inspection.
1/30/24, 3:24 PM SIS 2.0
3. Place a Rod Bolt onto the Gauge-Block. Do not apply any additional downward pressure. Give a
slight vertical rocking motion from the thread end to release any friction between the elastomer
material and the gauge block.
Side-by-side reuse comparison
(1) C175 Rod Bolt
(2) Elastomer material
(Left) Reusable C175 Rod Bolt
(Right) Non-Reusable C175 Rod Bolt
4. Refer to Illustration 24. If the elastomer material keeps the rod bolt elevated above the chamfers (left
side), then the rod bolt can be reused. If at any time the rod bolt slides into the gauge block groove
(right side), then the rod bolt cannot be reused.
5. Rotate the rod bolt approximately 1/8 of a rotation and repeat the rocking motion.
1/30/24, 3:24 PM SIS 2.0
Repeat Step 5 four more times until the bolt has been rotated 180° in the gauge block. This process
will ensure that the bolt has been measured entirely around the circumference.
Standard process to mark Main Stud after each time it is tightened

C175 main studs can be torqued up to 10 times two lives before replacement is necessary, which is the
equivalent of two lives. Marking the stud each time it is torqued will ensure that the stud is not used past
its intended service life. Mark the stud by stamping an X on the stud end every time the stud is torqued.
Stamp away from the outside of the stud near the threads to prevent damage to the stud. 25 and 26.
Example of stud without markings
Example of stud after stud has been tightened. Marks can be made with an X stamp. Be sure to stay away from thread area
when stamping.
1/30/24, 3:24 PM SIS 2.0
3600 and C280 Engine Fasteners

Use the following guidelines 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
Cylinder Head Studs

Replace any stud for the cylinder head after the stud has been tensioned 20 times. This criteria includes
the 1W-2363 Cylinder Head Taperlock Stud, 7E-8400 Cylinder Head Taperlock Stud, and 187-0450
Cylinder Head Taperlock Stud.
Main Bearing Cap Bolts and Studs

Replace any 3S-7079 Cross Tie Bolt for main bearing caps after the bolt has been tightened 5 times.
Replace any 1W-0121 Main Bearing Taperlock Stud after the stud has been tensioned 20 times.
Connecting Rod Bolts

Note: Document bolt usage , reused or new, in Simsi.cat.com to track service history and improve
reusability records.
Inspection of Rings on Connecting Rod Bolts
1/30/24, 3:24 PM SIS 2.0
Typical example of Connecting Rod Bolts
(1) Heat Shrink Tube
(2) Rings
(A) Distance from the bottom of the bolt head to the top of the Heat Shrink Tube should be 1.50 mm (0.05906 inch)
Typical example of ring wear patch.
Special attention should be paid to damage on connecting rod bolt rings (2).
Ring wear needs to be measured to determine reusability. To measure ring wear, use a micrometer
capable of 0.001 mm (0.00004 inch) accuracy with an anvil diameter of no more than 6.00 mm
(0.2362 inch).
1/30/24, 3:24 PM SIS 2.0
PIP
202 -1046
12: 4 / 0 4 666
2 1 / 3
SEB :49+ 0
4
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Illustration 29 0
Cat 4 C
Typical example of measuring ring wear. 2 1
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Do not measure more than 3 rings at a time. Start at the center of the wear patch and measure until the
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minimum diameter is found.
ntia Inc
If multiple wear patches are present, take a measurement in each central wear location until the
minimum diameter is found.
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llow
Position of Non-Alignment holes (5) and Alignment holes (6).
(4) small forging boss identifying the top alignment hole on the 348-7286 Connecting Rod Group.
Bolts that measure between 19.100 and 19.184 mm (0.7520 to 0.7553 inch) can only be reused in non-
alignment holes. Use a paint pen to mark the heads of these bolts with an N for Non-Alignment.
1/30/24, 3:24 PM SIS 2.0
Bolts that measure at 19.185 mm (0.7553 inch) or greater can be reused in any hole. Use a paint pen to
mark the heads of these bolts with an A for Alignment (or Any hole).
Caterpillar requires the use of 192-7870 Connecting Rod Bearings when reused bolts are installed in
Alignment holes (one or both holes). 227-2902 Connecting Rod Bearings may only be used when
BOTH alignment holes utilize new bolts.
Stamp the end of bolt ahead of reuse. This will be an indicator that it has ran one bearing life cycle and
could have been torqued up to 2 times. As the bolt gets reused for a 2nd life cycle it will receive up to 2
more torque events. Any bolt removed from an engine with a stamp on the end is presumed to have
received its maximum torques and should not be reused.
Typical example of R on a connecting rod bolt.
If the fasteners appear to be free of defects, also follow these guidelines:
Only connecting rod bolts with an R on the head are allowed to be used. Relevant bolt part numbers are
366-5099, 369–7181, and 467-0537.
1. Inspect connecting rod bolts at each service of the connecting rod bearings. There should be no
fretting on the shank annular ring area (2) of the connecting rod bolt. Ensure that the connecting rod
bolt meets the guidelines for the reusable parts. Do not reuse the connecting rod nuts.
2. Prior to installation of the new 467-0537 Bolt Assembly, inspect heat shrink tube (1). The tube serves
as an alignment sleeve for the bolts.
All 3600 and C280 connecting rod bolts must have a 369-7183 Heat Shrink Tube installed on the
bolt prior to installation.
a. The heat shrink tube (1) must be firmly in place and must not move under light finger pressure.
1/30/24, 3:24 PM SIS 2.0
b. The whole surface of the tube must be smooth.
c. The tube must not extend into the fillet that is under the bolt head.
3. If a problem is found with the tube, use the following replacement procedure.
a. Carefully remove the heat shrink tube from the bolt.
b. Ensure that there is no damage to the shank of the bolt that was under the tube.
c. Clean the shank of the bolt with solvent to remove any oil.
d. Install a new 369-7183 Heat Tube (1) onto the bolt. Position the tube up to 1.5 mm (0.0591 inch)
(A) under the bolt head, away from the fillet under the bolt head.
e. Use a heat gun or place the bolt and tube in an oven for 10 minutes. The tube must fit into place
without any bumps or wrinkles.
f. After the bolt cools, the tube must be firmly in place. The tube must not move under light finger
pressure.
g. Make sure that the surface of the tube is smooth all around. Verify that the tube does not extend
onto the fillet that is under the bolt head.
NOTICE
An overloaded bolt can be detected by threading a new
205-0640 Nut onto the bolt by hand. If the threads are not
damaged, the nut will easily reach the end of the bolt thread
with light finger pressure. If the nut stops before reaching the
end, do not reuse the bolt.
The 366-5099 Connecting Rod Bolt can only be reused if the

369-7183 Heat Shrink Tube has been properly installed on the
bolt.
Torque Turn Bolts
1/30/24, 3:24 PM SIS 2.0
Acceptable dimension for torque turn connecting rod bolts.
(B) Torque Turn Bolts cannot be longer than 329.00 mm (12.9527 inch). Do Not Use if measured above this value.
Note: Torque Turn Bolts may be tightened a maximum of 5 times. This includes retightening after
checking the rod bore or bearing clearance.
Do not reuse the connecting rod nuts.
Do not count de-tensioning as a tightening event.
For Torque Turn Bolts 369-7181, and 467-0537, refer to Engine News, SEBD9992 , "A New Torque
Procedure for Connecting Rod Bolts Is Now Used on 3600, G3600, and C280 Engines".
Hydraulic Tension Bolt
Acceptable dimension for hydraulic tension connecting rod bolts.
(C) Bolt 463-9619 cannot be longer than 360.90 mm (14.2086 inch). Do Not Use if measured above this value.
1/30/24, 3:24 PM SIS 2.0
Note: Hydraulic Tension Bolts may be tightened a maximum of 5 times. This includes retightening after
checking the rod bore or bearing clearance.
Do not reuse the connecting rod nuts.
Do not count de-tensioning as a tightening event.
Hydraulic tension bolts may be reused if they meet bolt reuse guidelines. An overloaded bolt can be
detected by threading a new 205-0640 Connecting Rod Nut onto the bolt by hand. If the threads are not
damaged the new connecting rod nut will easily reach the end of the bolt thread with light finger
pressure. If connecting rod nut stops before reaching the end, do not reuse the bolt.
PIP-10464666
2024/01/30
12:24:23+03:00
i03872789
© 2024 Caterpillar Inc.
Caterpillar:
Confidential Yellow

Inspection and Reuse of Critical Fasteners Used in All Engines

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Inspection and Reuse of Critical Fasteners Used in All Engines

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1/30/24, 3:24 PM SIS 2.

SMCS - 1000, 7553 i09902745

Introduction ntia Inc

Information contained in this document is considered Caterpillar: Confidential Yellow.

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Your safety is Involved.

Service Advisories, Service Letters, and Technical Service

Tooling and Equipment

Required Tooling and Equipment

Part Number Description

1. The head (1)

2. The under head fillet (3)

3. The bolt washer face (2)

4. The shank (4)

5. The bolt threads (5)

Do not use again

Fretting and Fretting Corrosion

Do not use again

Do not use again

Do not use again

Note: Pitting can cause bolts to crack.

Patch Lock Bolts

Adhesive Lock Bolts

Reduced-Diameter Shank Bolts

Bolt Cleaning Method

Reusability for Critical Fasteners in C - Series Engines

Critical Fasteners Reusability for C-series Engines (C7.2 through C32)

Fastener Type Reusability of Fasteners

Main Bolts Reuse at any rebuild if reuse criteria is met.

3500 Family Engine Bolt Reuse and Assembly Lube Type

Connecting Rod Bolts use Loctite ® LB 8012Moly Paste

First Second Fourth

C175 Engine Fasteners

Fastener Reusable Number of times reused

Flywheel Bolts N N/A

Note: Never reuse flywheel bolts.

C175 High-Pressure Fuel Rail Bolts

Visual Inspection of C175 428-7386 Bolt

Note: A CWS login is required to access Caterpillar Channel 1 Videos.

1. Clean the Gauge-Block with a lint free towel and solvent.

Standard process to mark Main Stud after each time it is tightened

3600 and C280 Engine Fasteners

Cylinder Head Studs

Main Bearing Cap Bolts and Studs

Connecting Rod Bolts

Inspection of Rings on Connecting Rod Bolts

If the fasteners appear to be free of defects, also follow these guidelines:

b. The whole surface of the tube must be smooth.

a. Carefully remove the heat shrink tube from the bolt.

The 366-5099 Connecting Rod Bolt can only be reused if the

Torque Turn Bolts

Hydraulic Tension Bolt

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