3508, 3512 and 3516 Engines Caterpillar

Connecting Rod Bearings

The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are fretted, check the bore size. This can be an indication of wear because of a loose fit.

Connecting rod bearings are available with 0.63 mm (0.025 inch) and 1.27 mm (0.050 inch) smaller inside diameter than the original size bearing. These bearings are for crankshafts that have been reground.

Main Bearings

Main bearings are available with a larger outside diameter than the original size bearings. These bearings are available for the cylinder blocks with the main bearing bore that is made larger than the bores' original size. The size that is available has a 0.63 mm (0.025 inch) outside diameter that is larger than the original size bearings.

Main bearings are available with 0.63 mm (0.025 inch) and 1.27 mm (0.050 inch) smaller inside diameter than the original size bearing. These bearings are for crankshafts that have been reground.

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. Alignment error in the bores must not be more than 0.08 mm (0.003 inch). Refer to 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 1	g00285686
1P-3537 Dial Bore Gauge Group

Projection Of Cylinder Liners

The liner projection above the spacer plate should be the following dimension:

1. Make sure that the top surface of the cylinder block, the liner bores, the spacer plates and the liner flanges are clean and dry.

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Illustration 2	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 bands.

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

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

   2. Install the following components: 8B-7548 Push-Puller Tool Group (6), the 3H-0465 Push-Puller Plate (1) and the two 8F-6123 Bolts. Ensure that the 8B-7548 Push-Puller Tool Group is in position at the center of the liner. Ensure that the surface of the liner is clean. Tighten the bolts evenly to a torque of 70 N·m (50 lb ft).

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

5. Use the 8T-0455 Liner Projection Tool Group to measure the 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 liner projection must be 0.059 to 0.199 mm (0.0023 to 0.0078 inch). Make the measurement to the outer flange of the liner. Do not make the measurement to the inner ring. The maximum difference between the high measurements and the low measurements that is made at four places around each liner should be 0.05 mm (0.002 inch).

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

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

Flywheel And Flywheel Housing

Face Runout (axial eccentricity) of the Flywheel Housing

Illustration 3	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. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

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Illustration 4	g00285932
Checking Face Runout Of The Flywheel Housing

3. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 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 (0.015 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 5	g00285934
8T-5096 Dial Indicator

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 6	g00285936

2. While the dial indicator is in the position at location (C) adjust the dial indicator to 0.0 mm (0.00 inch). Push the crankshaft upward against the top of the bearing. Refer to the illustration 68. 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 position (A). Adjust the dial indicator to 0.0 mm (0.00 inch).

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Illustration 7	g00285932
Checking Bore Runout Of The Flywheel Housing

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

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

7. Turn the flywheel counterclockwise in order to put the dial indicator at position (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 8	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.

11. The bore is in alignment, if the point of intersection is in the range that is marked "Acceptable". 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 9	g00286049
Checking Face Runout Of The Flywheel

1. Refer to illustration 71 and install the dial indicator. Always put 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 (0.00 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 10	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) so that the dial indicator makes contact on the flywheel.

2. Set the dial indicator to read 0.0 mm (0.00 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 bore runout (radial eccentricity) of the flywheel.

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Illustration 11	g00286058
Flywheel Clutch Pilot Bearing Bore

5. 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 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 at the time of a crankshaft failure due to torsional forces.