G3406 Engine Caterpillar


Cylinder Liner Projection

Usage:

G3406 1RK
Before you perform this procedure, make sure that the engine block, the spacer plate, and the cylinder liners meet the requirements that are published in the Specifications manual.

Table 1
Tools Needed  Qty 
1U-9895 Crossblock (1) 
3H-0465 Push-Puller Plate (1) 
8F-6123 Bolt (2) 
1P-2396 Adapter Plate 
8T-4193 Bolt  28 
2S-5658 Hard Washer  28 
8F-1484 Washer  28 
7K-1977 Washer  28 
8T-0455 Liner Projection Tool Group 
(1) This item is part of the 8B-7548 Push-Puller Tool Gp.
(2) Bolt size is 3/4 16 NF and 140 mm (5.5 inch).


    Illustration 1g00769678
    (1) 8T-4193 Bolt
    (2) 2S-5658 Hard Washer
    (3) 8F-1484 Washer
    (4) 7K-1977 Washer
    (5) Spacer plate
    (6) 1P-2396 Adapter Plate
    (7) 3H-0465 Push-Puller Plate

  1. Make sure that the top surface of the cylinder block is clean. Install a new plate gasket onto the cylinder block. Place spacer plate (5) onto the plate gasket.


    Illustration 2g00770644
    (1) 8T-4193 Bolt
    (2) 2S-5658 Hard Washer
    (3) 8F-1484 Washer
    (4) 7K-1977 Washer

    Note: The 7K-1977 Washer (4) is made of a cotton fabric that is impregnated with resin. The washer will not damage the sealing surface of the cylinder block.

  2. Secure the spacer plate to the cylinder block with bolts (1) and gaskets (2), (3) and (4). Tighten the bolts evenly in four steps:

    1. Tighten the bolts to a torque of 14 N·m (10 lb ft).

    2. Tighten the bolts to a torque of 35 N·m (25 lb ft).

    3. Tighten the bolts to a torque of 70 N·m (50 lb ft).

    4. Tighten the bolts to a torque of 95 N·m (70 lb ft).

    Note: Use the bare cylinder liners. Do not install the filler bands or the O-ring seals onto the cylinder liners yet.

  3. Make sure that the surfaces of the engine block, the cylinder liner, and the spacer plate are clean. Remove any nicks from the surface of the spacer plate.

  4. Place a cylinder liner into a bore. Fit adapter (6) onto the cylinder liner. Place plate (7) onto the adapter.


    Illustration 3g00740417
    (7) 3H-0465 Push-Puller Plate
    (8) 1U-9895 Crossblock
    (9) 8F-6123 Bolt
    (10) 8T-0455 Liner Projection Tool Group

  5. Use crossblock (8), two plates (7), and two bolts (9) to seat the cylinder liner in the bore. Tighten the bolts evenly in four steps:

    1. Tighten the bolts to a torque of 7 N·m (5 lb ft).

    2. Tighten the bolts to a torque of 20 N·m (15 lb ft).

    3. Tighten the bolts to a torque of 35 N·m (25 lb ft).

    4. Tighten the bolts to a torque of 70 N·m (50 lb ft).

      After the bolts are tightened, Measure the distance from the bottom edge of the crossbar to the surface of the spacer plate. The distance must be equal on both sides of the cylinder liner. If the distance is not equal, repeat the bolt tightening.

  6. Use the 8T-0455 Liner Projection Tool Group (10) to measure the cylinder liner projection.

    Note: The Special Instruction, SMHS7727 is provided with the tool group.



      Illustration 4g00770022
      8T-0455 Liner Projection Tool Group
      (11) Bolt
      (12) Dial indicator
      (13) Gauge body
      (14) Gauge block

    1. Loosen bolt (11) until dial indicator (12) can be moved. Place gauge body (13) and dial indicator (12) on the long side of gauge block (14).

    2. Slide dial indicator (12) downward until the point contacts gauge block (14) and the needle of the dial indicator moves to the vertical position. Tighten bolt (11). Zero the dial indicator.

    3. Place gauge block (14) on the spacer plate with the point of the dial indicator on the cylinder liner flange. Read the dial indicator in order to find the amount of cylinder liner projection.


      Illustration 5g00820559
      Points to measure around each cylinder liner

    4. Measure the projection of four points that are equally distant around each cylinder liner.

      If the projection is not within the “Cylinder liner projection” that is listed in Table 6, remove the cylinder liner. Turn the cylinder liner to a different position and seat the cylinder liner into the cylinder bore. Measure the projection again. If the projection will not meet the specifications, install the cylinder liner into a different bore.

    5. After the projection of the cylinder liner is within specifications, mark the radial position of the cylinder liner for the cylinder. Be sure to identify the particular cylinder liner with the corresponding cylinder.

    6. Make a copy of Table 2 for each cylinder. Record the measurements in the tables. Add the four measurements for each cylinder. Divide the sum by four in order to calculate the average projection for each cylinder liner. Record the averages in the tables.

      Table 2
      Cylinder Liner Projection 
      Cylinder number   
      Points  Measurement 
       
       
       
       
      Sum   
      Average   

    7. Make a copy of Table 3 for each cylinder in the cylinder head. Record the maximum measurement and the minimum measurement for each cylinder in the tables. Subtract the minimum measurement from the maximum measurement in order to determine the maximum variation for each cylinder liner projection in the cylinder head.

      Table 3
      Maximum Variation for Each Cylinder in the Cylinder Head 
      Cylinder number  Maximum 
      Cylinder number  Minimum 
      Variation   

    8. Make copies of Table 4 for each pair of adjacent cylinders. Record the average measurement for the adjacent cylinder liners in the tables. Determine the variation between the adjacent cylinder liners in the cylinder head. Record the variations in the tables.

      Table 4
      Variation of the Average Measurements for Adjacent Cylinder Liners in the Cylinder Head 
      Cylinder number  Average 
      Cylinder number  Average 
      Variation   

    9. Determine the cylinder with the greatest average measurement and the cylinder with the least average measurement. Record the measurements in Table 5. Subtract the minimum average measurement from the maximum average measurement in order to determine the maximum variation of all the cylinder liner projections in the cylinder head.

      Table 5
      Maximum Variation of All of the Cylinder Liner Projections in the Cylinder Head 
      Greatest average measurement   
      Least average measurement   
      Variation   

  7. Compare the results to the specifications that are listed in Table 6.

    Table 6
    Specifications for Cylinder Liner Projection 
    Cylinder liner projection  0.025 to 0.15 mm (0.0010 to 0.006 inch) 
    Maximum variation for each cylinder liner in the cylinder head  0.05 mm (0.002 inch) 
    Maximum average variation between adjacent cylinder liners in the cylinder head  0.05 mm (0.002 inch) 
    Maximum variation for all of the cylinder liners in the cylinder head  0.10 mm (0.004 inch) 

Result 1

The cylinder liner projection is correct. - The results meet the specifications that are listed in Table 6. Remove the cylinder liners and remove the tooling from the spacer plate. Install the filler bands and the O-ring seals onto the cylinder liners. Refer to Disassembly and Assembly, "Cylinder Liners - Install".

Result 2

One or more cylinder liner projections exceeds the maximum specifications. - At least one of the results exceed the specifications that are listed in Table 6. Use any of the following methods in order to correct the condition:

  • Machine the engine block. The 8S-3140 Counterboring Tool Group can be used. Refer to Instruction, FM055228. After the cylinder block is reworked, use the 2W-3815 Seat Insert and/or 5N-0093 Seat Insert in order to obtain the correct cylinder liner projection. For instructions, refer to Special Instruction, SMHS8222, "Installation of 2W-3815 or 5N-0093 Inserts".

  • Obtain new cylinder liners.

  • Obtain a new engine block.

Result 3

One or more cylinder liner projections is less than the minimum specifications. - At least one of the results is less than the maximum specifications that are listed in Table 6. Use any of the following methods in order to correct the condition:

  • Shim the cylinder liner. Use the inserts that are listed in “Result 2” in order to obtain the correct cylinder liner projection.

  • Obtain new cylinder liners.

  • Obtain a new engine block.

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