3500 Salvage Best Practices

MACHINE SHOP
Soledad (Atlántico) - Colombia

GENERAL INFORMATION
GECOLSA Machine Shop is leader in the reconstruction of parts and components of mining,
construction, marine, generation equipment and the Industry in general; counts with
qualified personal conformed by 245 technicians, divided in the following areas: Grinding
Area , Machining , Metal spray and Welding .
MACHINES
Area Description Qty Brand / Model Area Description Qty Brand / Model
Saro 1995 Rottler F88Y 2002
Conventional Yunnan 1992 Multipurpose Rottler F98Y 2007
5 4
Horizontal Lathe Uiangzu CNC Machine Rottler F99Y 2010
Romi 1996 Rottler F98Y 2011
Eastar 2012 Surfaces
1 Dimac 1995
Romi 2003 Grinding
CNC Horizontal Lathe 5 Crankshaft
Milltronics ML26 (3) 2008 2 Winona 1987
Grinding
GRINDING AREA
Rod Grinding 1 Winona 1996
Conventioal Vertical
1 Bullard 1968 Micropolish 1 QPAC 2012
Lathe
Hydrostatic
MACHINIG CNC Vertical Lathe 1 Hankook 2010 1 N. A. 1996
Testing Bench
Juaristic 1970
Conventional Boring Fadal
3 Hulstfred 1968 2002
Machine Vertical Machine VMC4020
Union 1974 2
Center Fadal VMC
Doosan DBC110 2010 2005
6535
CNC Boring Machine 3 TOTAL 12
Milltronics HM70 (2) 2011
Conventional Milling Area Name Qty Brand / Model
2 Rambo 1994
Machine TAFA - 8830 1999
CNC Milling Machine 1 Milltronics RH20 2011 Arc Spray 2
TAFA - 8830 2004
Radial Drill 1 Kovosvit 1993 Metco - Dual 1997
TOTAL 22 METAL SPRAY Flame Spray 2 Metco - 2004
UltraJet
Grind Blasting 1 Clemco 1998
Glass Bead 1 Clemco 1998
TOTAL 6
Machines
BORING MACHINE
SPECIFICATIONS:
•Table size: 1400 x 1800 mm
•Load Capacity: 10 Ton
•Number of tools: 60
Funtions: Boring, drilling, thread, griding, milling
Target: Carriers, Engine Housings, Transmission Housings, Wheels, Roller Frames, Rear and front
axle, etc.
Production Information: 40% less machining time on banjo housing of 793 trucks
Brand: Doosan
Model: DBC-110.
VERTICAL LATHE
SPECIFICATIONS
•Capacity: 2000 mm
•Maximun Legth: 1400 mm
•Number of tools: 24
Functions: Boring, drilling, thread, slot.
Target: Differential Carriers , Wheels, Spindle, Anchor brake ,
pistons, Idler
Production Information: 45% less machining time of spindle of truck
793
Brand: Hankook.
Model: VTC-160E.
Machines
SPECIFICATIONS
•Capacity: 3000 mm
•MaximunLegth: 1000 mm
Functions: Griding face, boring main bearing block and camshaft holes of block CAT 3500,
machining in three axle (CNC), drilling
Target: Cilynder block, cilynder head, coneccting rod, etc.
Production information: Rebulding capacity : 20 blocks per month
Brand: Rottler.
Model: F98Y (2), F99Y (1) y F88S(1).
SPECIFICATIONS:
•Capacity: 600 mm
•MaximunLegth: 2000 mm
•Load Capacity: 1.5 Ton
Functions: Boring, drilling, thread, griding, milling.
Target: Housing Clucht, shaft; trunnion, support
trunnion, spindle, yoke, gears, bushings, piston etc.
Production Information:
30% less machining time of part rebulding.
Brand: Milltronics.
Model: ML26/80
Machines
SPECIFICATIONS:
•Maximun Legth: 1200 mm
•Load Capacity: 900 kg
Functions:
Boring, drilling, thread, griding, milling.
Target:
Half housing, piston, elbow, carrier, caps engine, housing clucht, tools, etc.
Production information:
30% less machining time of part rebulding
Brand: Milltronic
Model: RH20
SPECIFICATIONS:
•Maximun Legth: 2 m
•Load Capacity: 10 ton
Functions: Boring, drilling, thread, griding, milling.
Target: Housing Clucht, shaft; trunnion, support trunnion, spindle, yoke, gears,
bushings, piston etc.
Production information:
30% less machining time of part rebulding
Brand: Hankook
Model: VT100
PRODUCTION (NUMBER OF PIECES)
Monthly
Acumulated
1. CYLINDER BLOCKS ARRIVES WITH SS INSERTS IN THE WATER PORTS AND SS LINER
INSERT IN THE COUNTER BORE
Check the block

2. SPECIFICATIONS OF LINER INSERT AND COUNTER BORE
Remove of the SS liner insert

Machining of the counter bore 7 mm depth.
Instalation of the liner cast iron insert, with an internal diameter menor of 3 mm of the standard
specification.
CAST IRON INSERT MEASURES

Outside Diameter 212.1154 mm
Internal Diameter 195.58 mm
Height 7 mm
COUNTER BORE MEASURES

Internal Diameter 212.0354 mm
Depth 7 mm
3. INSTALATION OF CAST IRON LINER INSERT
MATERIAL ASTM A48 CAST IRON
Installing of the insert

4. PREMACHINING OF SPOTFACE
Premachining of spotface 1 mm of depth.
Premachined spotface
PARAMETERS OF MACHINING
RPM 400
Advance (Vf) 250 mm
Depth of Cut 0.500 mm
5. INSERT TYPE AND TOOL USED TO MACHINING THE SPOTFACE
PARAMETERS MEASURES
Cut Depth 1 mm
Diameter 287.02 mm
Face Milling cutting

Ref Insert:
PDKT0905DEER-41 5020
6. GRIT BLASTING
GRIT BLASTING PARAMETERS

Pressure 100 PSI
Distance 7-8”
7. ARC SPRAY
Arc spray: Equipment: TAFA 8830.
Arc Spray Gun 8830
Arc Spray Spot Face

8. ARC SPRAY PARAMETERS
VARIABLE OPERATION RANGE

Voltage 35V
Current 100-150 Amp
Pressure 50 PSI (345 Kpa)
Distance between gun and workpiece 5" - 7" (127-177.8 mm)
0.039"-0.080" (1-2 mm)

Thickness Layer (Measure Initial
Temperature 100-130°C
9. ARC SPRAY EQUIPMENT
MATERIAL SULZER
REF SM8400
DIAMETER 1/16”
Equipment: ARC SPRAY TAFA 8830
Net WT 26 lbs.
Kgs. 11.79
10. MACHINED DECK
 FINAL MACHINED.
Maximum roughness <
100 micro inches.
Average: 60 micro inches.
MACHINING PARAMETERS FINISHING PARAMETERS

Cutting Speed 140 RPM Cutting Speed 140 RPM
Advance (Vf) 0.762 mm Advance (Vf) 0.3048 mm
Depth of Cut 0.127 mm Depth of Cut 0.127 mm
11. INSERT TYPE AND TOOL USED IN THE MACHINING OF THE CYLINDER BLOCK
DECK
Insert Reference: Walter.

SNMX1205ANN-F57 WKP35.
Face Milling cutting

Made in: Colombia.
Number of insert: 10
Weight: 10 kg.
Material: Duraluminum
12. CYLINDER BLOCKS ARRIVES WITHOUT SS INSERTS IN THE WATER PORTS AND
WITHOUT SS LINER INSERT
Premachining Spotface.
13. GRIT BLASTING
PARAMETERS OF GRID BLASTING

Pressure 100 PSI
Distance 7-8”
14. ARC SPRAY
Arc spray
Arc Spray Spot Face

15. MACHINED DECK
FINAL MACHINED
Maximum roughness <
100 micro inches.
Average: 60 micro inches.
Machined Deck
16. CYLINDER BLOCKS ARRIVES WITH SS INSERTS IN THE WATER PORTS AND SS
LINER INSERT IN THE COUNTER BORE, WITH OVERLAPING
Stainless steel insert are removed.
Intersección (Traslape)
17. SS INSERT OF WATER PORT ARE REMOVED
Insertos puertos de
Agua Removidos
18. INSTALATION OF CAST IRON INSERT AND PREMACHINED
 Inserto de Fundicion Gris Insertos de Puertos de Agua

instalado en Asiento de Camisa Removidos.
19. GRIT BLASTING
PARAMETROS DE GRIT BLASTING

Presión 100 PSI
Distancia 7-8”
20. ARC SPRAY
ARC SPRAY – ALAMBRE METCO 8400 (ALTERNATIVA TAFA 75B)
Superficie Metalizada con Arc Spray sobre los puestos Spot Face incluyendo
puertos de agua rellenos por metalizados.
21. MACHINED DECK
RECTIFICADO FINAL
Maxima rugosidad < 100
micro inches.
Promedio : 60 micro
inches.
Machined Deck
22. CYLINDER BLOCKS DECK ENTIRE ARC SPRAY
Before Arc spray deck

23. ARC SPRAY
Arc spray deck

24. MACHINED DECK
Final machined of deck with roughness 35-60 µin

25. CYLINDER BLOCKS ARC SPRAY
Arc Spray Cylinder Blocks 3500 Salvaged
SPRAY OVER CAST IRON CYLINDER LINER INSERTS 46
SPRAY SPOTFACE ONLY (W/OUT INSERTS) 8

SPRAY ENTIRE DECK
50 Blocks
HEIGHT RECOVERY ONLY W/OUT INSERTS)
TOTAL 104

3500 Salvage Best Practices

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MACHINE SHOP

Soledad (Atlántico) - Colombia

Check the block

Remove of the SS liner insert

CAST IRON INSERT MEASURES

COUNTER BORE MEASURES

MATERIAL ASTM A48 CAST IRON

Installing of the insert

Premachining of spotface 1 mm of depth.

Face Milling cutting

GRIT BLASTING PARAMETERS

Arc spray: Equipment: TAFA 8830.

Arc Spray Gun 8830

Arc Spray Spot Face

VARIABLE OPERATION RANGE

Distance between gun and workpiece 5" - 7" (127-177.8 mm)

0.039"-0.080" (1-2 mm)

MACHINING PARAMETERS FINISHING PARAMETERS

Insert Reference: Walter.

Face Milling cutting

PARAMETERS OF GRID BLASTING

Arc Spray Spot Face

Stainless steel insert are removed.

 Inserto de Fundicion Gris Insertos de Puertos de Agua

PARAMETROS DE GRIT BLASTING

ARC SPRAY – ALAMBRE METCO 8400 (ALTERNATIVA TAFA 75B)

Before Arc spray deck

Arc spray deck

Final machined of deck with roughness 35-60 µin

Arc Spray Cylinder Blocks 3500 Salvaged

SPRAY OVER CAST IRON CYLINDER LINER INSERTS 46

SPRAY SPOTFACE ONLY (W/OUT INSERTS) 8

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