3306B Industrial Engine Caterpillar

Piston Rings

Illustration 1	g00365332
Instructions for the 1U-6431 Piston Ring Groove Gauge

Some engines have piston grooves and rings of the keystone design (taper). The 1U-6431 Piston Ring Groove Gauge is available to check the top two ring grooves in the piston. For the correct use of the gauge, refer to the instruction card that is with the gauge.

Pistons with Straight Sides in the Ring Grooves

A 5P-3519 Piston Ring Groove Gauge is available for checking piston ring grooves with straight sides. Refer to Special Publication, SEBF8049, "Guideline for Reusable Parts (Pistons)" for instructions.

Connecting Rods and Pistons

Use the 7S-9470 Piston Ring Expander to remove or install piston rings.

Use the 5P-3525 Piston Ring Compressor in order to install pistons into the cylinder block.

Tighten the connecting rod nuts in the following sequence:

1. Before you install the connecting rod bolts, lubricate the bolt threads and the seating faces of the caps with 6V-4876 Lubricant .

2. Tighten the bolts to the following torque. 40 ± 4 N·m (30 ± 3 lb ft)

3. Place an alignment mark on each cap and on each bolt head.

4. Tighten each bolt for an additional 90 ± 5 degrees (1/4 of a turn).

Connecting Rod Bearings

The connecting rod bearings must fit tightly into the bore in the rod. A loose fit is an indication of wear. If the bearing joints or the backs are worn, check the bore size. If the matching joints are fretted, check the bore size.

Note: Connecting rod bearings are available with undersized inside diameters. The inside diameters are undersize by the following dimensions:0.25 mm (.010 inch), 0.51 mm (.020 inch) and 0.76 mm (.030 inch). If the undersized connecting rod bearings are used for repair, the crankshaft must be machined.

Main Bearings

Main bearings are available in different sizes. The different sizes are used for repair. Some main bearings have undersized inner diameters. Some main bearings have oversized outer diameters. Some main bearings have both undersized inner diameters and oversized outer diameters. These bearings are available for cylinder blocks and/or crankshafts that need to be machined in order to be repaired.

Note: Refer to the Parts Manual for additional information on Main Bearings and Journals.

Cylinder Block

If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications, "Cylinder Block". Alignment error in the bores must not be more than 0.08 mm (.003 inch).

Refer to the Special Instruction, SMHS7606 for the use of the 1P-4000 Line Boring Tool Group for the alignment of the main bearing bores. The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.

Illustration 2	g00285686
1P-3537 Dial Bore Gauge Group

Projection Of Cylinder Liners

1. Make sure that the top surface of the following components are clean and dry:
   • Cylinder block

   • Cylinder liner bores

   • Spacer plates

   • Cylinder liner flanges

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Illustration 3	g00285687
Measuring the Liner Height Projection (1) 3H-0465 Push Puller Plate. (2) Dial Indicator. (3) 1P-2402 Gauge Body. (4) 0S-1575 Bolt. (5) Spacer plate. (6) 8B-7548 Push-Puller Tool Group .

2. Install a new gasket and spacer plate (5) on the cylinder block.

3. Install the cylinder liners in the cylinder block without seals or without bands.

4. Hold the spacer plate and the cylinder liner in position according to the following procedure:

   1. Install four 0S-1575 Bolt (4) and washers around each cylinder liner. Tighten the bolts evenly to a torque of 95 N·m (70 lb ft).

      Ensure that the surface of the cylinder liner is clean.

   2. Install the following items:
      • The 8B-7548 Push-Puller Tool Group (6)

      • The 3H-0465 Push Puller Plate (1)

      • Two 8F-6123 Bolts

      Determine that the 8B-7548 Push-Puller Tool Group is in the proper position at the center of the cylinder liner.

   3. Check the distance of the edges from the bottom of the 8B-7548 Push-Puller Tool Group (6) to the top of the spacer plate. The distance on each end of the 8B-7548 Push-Puller Tool Group must be equal.

5. Use the 8T-0455 Liner Projection Tool Group to measure the cylinder liner projection.

6. Mount the dial indicator (2) in the 1P-2402 Gauge Body (3). Use the back of the 1P-5507 Gauge Block to zero the dial indicator (2).

7. The cylinder liner projection must be 0.033 to 0.175 mm (.0013 to .0069 inch). Make the measurement to the outer flange of the cylinder liner. Do not make the measurement to the inner ring. The maximum difference between the high measurements and the low measurements that are made at four places around each cylinder liner should be 0.05 mm (.002 inch).

Note: If the cylinder liner projection changes around the cylinder liner, turn the cylinder liner to a new position within the bore. If the cylinder liner projection is not within specifications, move the cylinder liner to a different bore. Inspect the top face of the cylinder block.

Note: When the cylinder liner projection is correct, mark the cylinder liner and the spacer plate. When the seals and the band are installed, the cylinder liner can be installed in the correct position.

Flywheel And Flywheel Housing

Face Runout (Axial Eccentricity) of the Flywheel Housing

Illustration 4	g00285931
8T-5096 Dial Indicator Group

If you use any other method except the method that is given here, always remember that the bearing clearance must be removed in order to receive the correct measurements.

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel housing.

2. Lightly force the crankshaft toward the rear before the dial indicator is read at each point.

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Illustration 5	g00285932
Checking Face Runout Of The Flywheel Housing

3. Turn the flywheel while the dial indicator is set at 0.0 mm (.00 inch) at location (A). Read the dial indicator at locations (B), (C), and (D) .

4. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.38 mm (.015 inch), which is the maximum permissible face runout (axial eccentricity) of the flywheel housing.

Bore Runout (Radial Eccentricity) of the Flywheel Housing

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Illustration 6	g00285934
8T-5096 Dial Indicator Group

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the flywheel housing.

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Illustration 7	g00285936

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Illustration 8	g00285932
Checking Bore Runout Of The Flywheel Housing

2. While the dial indicator is in the position at Location "C", adjust the dial indicator to 0.0 mm (.00 inch). Push the crankshaft upward against the top of the bearing. Refer to the Illustration 7. Write the measurement for bearing clearance on Line "1" in Column "C".

   Note: Write the measurements for the dial indicator with the correct notations. This notation is necessary for making the calculations in the chart correctly.

3. Divide the measurement from Step 2 by two. Write this number on Line "1" in Columns "B" and "D".

4. Turn the flywheel in order to put the dial indicator at (A). Adjust the dial indicator to 0.0 mm (.00 inch).

5. Turn the flywheel counterclockwise in order to put the dial indicator at (B). Write the measurements in the chart.

6. Turn the flywheel counterclockwise in order to put the dial indicator at (C). Write the measurement in the chart.

7. Turn the flywheel counterclockwise until the dial indicator is at (D). Write the measurement in the chart.

8. Add the lines together in each column.

9. Subtract the smaller number from the larger number in Column "B" and Column "D". Place this number on Line "III". The result is the horizontal eccentricity (out of round). Line "III" in Column "C" is the vertical eccentricity.

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Illustration 9	g00286046
Graph For Total Eccentricity (1) Total vertical eccentricity. (2) Total horizontal eccentricity. (3) Acceptable value. (4) Unacceptable value.

10. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

    1. If the point of intersection is in the range that is marked "Acceptable", the bore is in alignment.

    2. If the point of intersection is in the range that is marked "Not Acceptable", the flywheel housing must be changed.

Face Runout (Axial Eccentricity) of the Flywheel

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Illustration 10	g00286049
Checking Face Runout Of The Flywheel

1. Refer to Illustration 10 and install the dial indicator. Always apply a force on the crankshaft in the same direction before the dial indicator is read. This will remove any crankshaft end clearance.

2. Set the dial indicator to read 0.0 mm (.00 inch).

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value must not exceed the maximum permissible face runout (axial eccentricity) of the flywheel.

Bore Runout (Radial Eccentricity) of the Flywheel

Illustration 11	g00286054
Checking Bore Runout Of The Flywheel (1) 7H-1945 Holding Rod. (2) 7H-1645 Holding Rod. (3) 7H-1942 Dial Indicator. (4) 7H-1940 Universal Attachment .

1. Install the 7H-1942 Dial Indicator (3). Make an adjustment of the 7H-1940 Universal Attachment (4) until the dial indicator contacts the flywheel.

2. Set the dial indicator to read 0.0 mm (.00 inch).

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Record the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value must not exceed the maximum permissible bore runout (radial eccentricity) of the flywheel.

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Illustration 12	g00286058
Flywheel Clutch Pilot Bearing Bore

5. Record the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value must not exceed the maximum permissible pilot bore runout of the flywheel.

Vibration Damper

Damage to the damper or failure of the damper will increase vibrations. This will result in damage to the crankshaft.

Replace the damper if the damper is bent or damaged. Replace the damper if the bolt holes are oversize. Replacement of the damper is also needed after a crankshaft failure due to torsional forces.