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*Rev. D .
ELECTRO-MOTIVE DIVISION • GENERAL MOTORS CORPORATION

MAINTENANCE INSTRUCTION
CRANKCASE LOWER DECK REPAIR

INTRODUCTION 6. Be sure crankshaft journals of all removed cyl-

inder assemblies are protected from weld spatter
The following procedures will ensure satisfactory field and chip damage by wrapping them with clean
repair of engines which have damaged lower crankcase towels and covering them with sheet metal.
bores. Original dimensions are restored by building up
damaged bores with weld and reboring. Boring bars are 7. Make a sheet metal chute to go under the liner
available from the Electro-Motive Division on a rental plates where welding and boring will be done.
basis. This procedure may be used when it has been de-
termined that only a small percentage of bores in a WELDING PROCEDURE
crankcase need repair. It can be employed with the en-
gine in place unless other damage requires removal of WARNING: To provide adequate fire protection, fire
crankcase from oil pan. Crankcases with excessive lower extinguishers must be available near the
bore damage (50% or more cylinders), should be altered repair area. A person should be on hand
to receive 1.52 mm (.060") oversize outside diameter at all times to act as fire watch.
lower liner inserts. See Service Data. These liner inserts
are to be installed in full engine sets only and require It is suggested that all persons concerned with the pro-
that the engine be removed to be rebored. Use of the cedures given in this instruction be familiar with gen-
portable lower deck boring bar is not recommended in eral engine crankcase welding and repair.
this case.
CAUTION: Never ground welding circuit through mov-
All crankcases containing any oversize parts, including ing parts of the engine. Ground welding
lower liner inserts, must be identified by a revised en- circuit as close as possible to the work.
gine data plate 8163005 mounted to the right bank side This will eliminate possible arcing
of the crankcase. through bearings and moving parts of the
engine.
PREPARATION FOR REPAIR 1. Pack area adjacent to repair area with wet rags to
1. Remove the complete cylinder assemblies conduct heat, but do not allow them to contact the
from the damaged bore and from both adjacent weld. The rags should not be so wet that water will
bores in that bank. Remove the cylinder assembly come in contact with weld material. Every effort
directly opposite the damaged bore. should be taken to minimize the heat of welding.
After each weld, cool area with water. With the
2. Remove lower liner insert from damaged bore. exception of the first bead, following weld buildup
Refer to Engine Maintenance Manual. should be peened to relieve stresses.
3. Clean engine and oil pan throughout. NOTE: Weld repair of the cylinder lower pilot bores or
insert bores of the crankcase due to wear or mi-
4. Make light gauge sheet metal covers for rear stress nor damage does not require furnace stress re-
plate inspection holes and for liner deck plate lief. However, furnace stress relief is required
holes where assemblies have been removed. for multiple power assembly failure damage
with damaged stress plates and/or base rails.
5. Mask off area so that no foreign material can get
Crankcases requiring furnace stress relief should
into adjoining liner ports of cylinder assemblies
be returned to Electro-Motive for remanufacture.
remaining in the engine.

*Information contained herein is applicable to equipment being produced as of the date of publication.
DE-LMPR February 1977

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M.I. 315
2. Thoroughly clean and dry surface to be welded. nished for the right-hand crab to allow enough crab
bolt threads to protrude through it to apply the air mo-
3. Build up the damaged areas by electric welding; tor stop, Fig. 1. This stop acts as an anchor for the air
using Class E-6012 electrode, 3.18 mm (1/8") diame- motor, preventing it from revolving. Tighten each crab
ter only, with straight polarity DC or AC. nut to a torque value of 135.5 N-m (100 ft-lbs).

4. If any scarfing is necessary, it should be done by

grinding or chipping. Use of a cutting torch is not rec-
ommended. Nicks in the "A" frame or stress plates
should be dimpled out with a grinding wheel. Care
should be taken to smooth out all sharp edges.

5. Using a series of unbroken stringer beads, apply a

7.93 mm (5/16") weld bead at the upper and lower
edges of the lower pilot bore and around the center of
the bore.

6. The very first weld metal applied around the cir-

cumference of the repair area is the metal that will be
bored for the finished job. If there is any question of
the quality of weld deposit, it should be removed im-
mediately and rewelded. This will eliminate removal
of the boring bar to reweld later.

BORING BAR APPLICATION

CAUTION: The boring bar is a precision tool. Due

care must be exercised in its handling
and use.

Before placing the boring fixture in the cylinder, clean

the cylinder head retainer thoroughly. Wire brush the
interior to remove any loose carbon and clean the cyl-
inder head seat ring seating surface. Fig. 1 - Boring Bar Application
The boring bar is designed to be used with a cylinder Fig. 2 shows the feed screw depth nut gauge and its
head seat ring. A new seat ring should be used, since a application. This gauge is used to check the location
worn seat ring would lower the horizontal cuts to the of the feed screw depth nut in relation to the top of the
extent of the reduction of seat ring thickness. feed screw and is furnished as a means of checking
setup of the fixture. The feed screw depth nut adjust-
When using boring bar assembly, check to see that the ment should not change, as it is pinned to the feed
pilot ring is applied to the bar. Also check that the screw, but should be checked.
centering bracket fixture is applied to the head of the
bar. When the centering bracket is properly entered in It is imperative that a multivane non-reversible air
the water hole, and the fixture torqued, the bar will motor be used for this work. Never use a piston type
seat correctly on the seat ring. motor because the pulsation between each power
stroke will make the cutting tool chatter. NOTE:
Lift the fixture by the eye bolts provided, and lower When lubrication of the boring bar is required, apply
fixture into cylinder bore. Be sure the fixture is prop- Texaco Marfax Heavy Duty No. 3 grease to all gears
erly seated in the retainer before applying the cylinder and bearings.
head crabs. A special machined thin crab nut is fur

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excess metal has been cut out, remove the rough bore
cutting tool.

A rough or first cut should be made on each cutting

application being sure to leave 0.38 mm (.015") for
finish cut. After all rough cuts are made, a thorough
inspection must be made of the machined surface. If
any defects are found, remove the boring bar and
completely grind out the defect. Reweld the affected
area and reinstall the boring bar to make the finish
cuts.
NOTE: All defects must be patched before the finish
cut is made, as welding after the finish cut
will draw the holes out of round.
Three sets each of the bore diameter and seat tool bits
are standard equipment with boring bar assembly
8215546. However, as in any good machining opera-
tion, it is highly recommended that the rough cuts be
made with one of these tool bits and finish cuts be
made with another bit. This procedure, in conjunction
with the use of a coolant while boring, will ensure a
smooth and proper finish. See tool bit minimum grind
length limits in Service Data at the back of this in-
struction.

ENGINE MACHINING
Machine the lower liner vertical bore first, then the
lower liner counterbore.
LOWER LINER INSERT BORE
1. After making a cleanup pass through the bore,
make sufficient rough cuts to leave approxi-
mately 0.38 mm (.015") for the finish cut.
2. To set the tool bit for the finish bore, apply an
unused tool bit to the holder. Insert gauge in
place in the slot at the bottom of the tool holder
Fig. 2 - Lower Deck Boring Bar Machining Details so the end contacts the locating pin as shown in
Fig. 2. Carefully slide the tool bit out until it just
REBORING PROCEDURE contacts the radius of the inner face of the
gauge. Tighten tool bit holding screws securely.
Before attempting to machine out the bore diameters, This sets the tool bit for the finish diameter.
be sure the bore circumference has not been reduced
by weld buildup so that the tool bit holder strikes the 3. Make a trial finish cut slightly into the bore.
added metal. This can be done since the counterbore is yet to
be machined. Check the bore with an inside mi-
A rough bore cutting tool, Fig. 2, has been developed crometer. If the diameter is correct, continue the
for the purpose of cutting out this excess metal so the finish bore, or reset the tool bit if required to ob-
tool holder will clear it. Insert the cleanup cutter into tain a finish diameter as specified in the Service
the tool holder as far as it will go. It may be necessary Data.
to back off the tool bit feed screw to allow the tool bit
to rest against the body of the tool holder. After the

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INSERT COUNTERBORE
5. Charge engine with recommended coolant and
1. The insert counterbore is machined to the di- lube oil, and prelube as follows.
ameter specified in Service Data.
NOTE: On engines not equipped with a lube oil
2. Depth of the counterbore is limited by using the strainer housing, perform standard prelube
depth gauge under the feed screw depth nut as procedure for the specific engine configura-
shown in Fig. 2. tion.
3. Make sufficient rough cuts on the diameter and a. Remove the pipe plug at the main lube oil
depth to allow about 0.38 mm (.015") for the pump discharge elbow, and connect an ex-
finish cut. To permit the 0.38 mm (.015") depth ternal source of clean, warm oil at the dis-
finish cut, place the depth gauge on the gauge charge elbow. Prelube engine at a minimum
button of the tool head, and using a 0.38 mm of 69 kPa (10 psi) for a period of not less
(.015") feeler gauge between the gauge button than three and not more than five minutes.
and depth gauge, feed down for the cut until the
depth nut is just snug on the feeler gauge. b. Remove the pipe plug at the piston cooling
oil pump discharge elbow and connect the
4. The finish cut is then made by feeding down un- external oil source at that opening. Check
til the depth nut contacts the depth gauge. For for unrestricted oil flow at each piston cool-
the finish diameter, the tool bit gauge is placed ing tube.
in the tool holder as shown in Fig. 2, and the
tool bit is brought out to just contact the radius c. Disconnect the external oil source and re-
of the inner face of the gauge. place the pipe plugs at the pump discharge
elbows.
NOTE: The tool bit has the bottom of the shank ground
flush with the cutting edge, to maintain correct d. Apply oil liberally at the engine top deck.
depth when using the depth gauge.
e. On turbocharged engines, activate the aux-
PREPARING ENGINE FOR SERVICE iliary turbo lube oil pump motor. Look
through a rear handhole for oil flow at the
STRESS PLATE INSPECTION turbocharger end of the engine.
Cleaning up damaged stress plates is very important, but
an attempt should never be made to straighten bent stress f. Replace and securely close all handhole
plates. All ragged or torn metal and all sharp edges must covers.
be removed, and all nicks must be dimpled out. Be sure 6. Engine starting procedure:
stress plate inspection holes have a smooth airflow con-
tour. Any of these defects left uncorrected can eventually a. Check oil level at the engine governor and at
cause cracks to occur in the stress plates. the square opening of the lube oil strainer.
Make certain that the strainer housing is full.
1. Clean engine thoroughly. It is imperative that all
steel and carborundum residue be removed. b. Check engine coolant level.
2. Spray wash and wipe engine.
c. Open cylinder test valves and bar over the en-
3. Flush engine lubricating system in accordance gine at least one revolution; check for leakage
with Maintenance Instruction 1757, using pro- from test valves. Close the test valves.
cedure given for flushing after a parts failure.
d. Properly position operating controls and
4. Install lower liner inserts and cylinder assemblies switches.
according to Engine Maintenance Manual rec-
ommendations. e. Prime the fuel system. On units so equipped,
check that fuel flows in the return fuel sight
CAUTION: Once the engine has been altered to accept glass clear and free of bubbles.
oversize lower liner inserts, standard inserts
must not be used.

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f. Position the governor rack control lever
(layshaft lever) at about one-third rack, then Run with proper governor setting and at rated
operate the engine start switch until the en- horsepower at approximately one-half, three-
gine fires and speed increases. quarter, and full speed for 30 minutes at each
speed. Shut engine down and check rod and
g. Hold the rack control lever firm until the en- main bearing temperatures.
gine fires and comes up to idle speed.
8. Run engine one hour at full engine speed and
7. Run engine unloaded for 10 minutes at idle rated load.
speed with top deck covers open to make certain
that valve mechanism is operating properly and 9. Inspect and clean lube oil suction screens. Re-
that there is sufficient lubrication. Shut engine new lube oil filters.
down and inspect rod bearings and main bear-
ings for excessive heat by feel. Run engine 10. Check governor settings, injector racks, injector
loaded for 30 minutes at one-quarter speed and timing, and engine speeds.
once again shut down and inspect rod bearings
and main bearings for overheating.

SERVICE DATA
SPECIFICATIONS
Standard lower liner insert (Fig. 3),
Bore finish diameter . . . . . . . . . . . . . . . . . . . . . 280.97-281.13 mm (11.062"-11.068")
Counterbore - Preferred diameter . . 287.30-287.38 mm (11.311 "-11.314")
Nominal diameter ..................... 287.10-287.57 mm (11.302"-11.322")
Oversize lower liner insert (Fig. 3),
Bore finish diameter . . . . . . . . . . . . . . . . . . . . . 282.49-282.66 mm (11.122"-11.128")
Counterbore - Preferred diameter ............... 289.69-289.77 mm (11.405"-11.408")
Nominal diameter ..................... 289.45-289.96 mm (11.396"-11.416")

Fig. 3 - Identifying Grooves, Oversize And Standard Lower Liner Inserts

NOTE: Oversize lower liner inserts are installed in full engine sets only. Engine must be removed and bored to new
oversize dimensions. Once the crankcase has been rebored to accept oversize inserts, standard inserts must
not be used.

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SERVICE DATA (Cont'D)

Minimum grind length for tool bits.

8089561 .................................... 76.99 mm (3-1/32")
8089562 .................................... 73.81 mm (2-29/32")
8102657 ..................................... 66.68 mm (2-5/8")

EQUIPMENT
Part No.
*Tool bit 25.4 mm x 25.4 mm x 88.9 mm (1 " x I" x 3-1/2 for
287.30 mm (11.311 ") bore . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . 8089561
*Tool bit 25.4 mm x 25.4 mm x 77.79 mm (I" x 1 " x 3 -1/16 1) for
280.97 mm (11.062") bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8089562
*Tool bit for clean-up boring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8102657
Air motor stop . . . . . . . . . . . . . . . . . . . . .. . . 8152217
Crab nut ............................................ 8190454
Lower deck boring bar assembly (complete) ......................... 8215546
*Lower deck boring bar .................................... 8215547
*Depth gauge 44.361 mm x 44.336 mm (1.7465"-1.7455") for insert counterbore . . . . . 8215548
*Tool bit gauge for 287.38 mm (11.314") insert counterbore ................ 8215550
*Tool bit gauge for 281.06 mm (11.065") insert bore .................... 8215552
Pilot ring for 307.08 mm (12.090") upper pilot bore .................... 8215554
*Eye bolt ............................................ 8239466
Air motor, non-reversible, multivane ............................. 8359402

*Included in lower deck boring bar assembly 8215546

For rental information, contact your EMD District Representative.