Usage:
Start By:
a. remove spacer plates
b. remove pistons
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates.
1. Remove the piston from the cylinder liner that is to be removed. See the topic, "Remove Pistons".
2. Turn the crankshaft so that the counterweights on the crankshaft are away from the bottom of the cylinder liner as shown.
3. Install Tool (A). Use Tool (A) to remove cylinder liner (1) from the block.
4. Remove filler band (2) and seals (3) from the cylinder liner.
5. Repeat Steps 1 through 4 for the other cylinder liners if necessary.
Install Cylinder Liners
NOTE: This procedure eliminates the need for the "H" bar to hold down the liners during projection measurements.
1. Make sure the bores of the engine block and the cylinder liners are clean. Install cylinder liners (1), without the filler band or seals, in the engine block.
2. Install a clean spacer plate gasket and a clean spacer plate.
3. Install fabric material washer (7K-1977), washer (8F-1484) and bolts (2) (7H-3598). Install the bolts (viewed from the rear of the engine) at 1-3-9-11 O'clock positions. Tighten the bolts to a torque of 95 N·m (70 lb ft).
4. Check the liner projection with Tool (A) at four locations around the liner flange at 2-4-8-10 O'clock positions (between the bolts). Liner projection must be 0.025 to 0.152 mm (0.001 to 0.006 in). The difference between the four measurements on the same liner must not be more than 0.051 mm (0.0020 in). The difference between average liner projection for liners next to each other must not be more than 0.051 mm (0.0020 in). The maximum difference in the average projection of the cylinder liners under each cylinder head must not be more than 0.102 mm (0.0040 in).
NOTE: If the liner projection changes too much from point to point around the liner, turn the liner to a new position in the bore. If the projection measurements are still not within specifications, move the liner to a different bore in the cylinder block and check the projection again.
NOTE: If the liner projections are all below the specifications or low in the range, 0.025 mm (0.001 in) or 0.051 mm (0.0020 in), try using a thinner spacer plate. These plates are 0.076 mm (0.003 in) thinner than the regular plate and they will increase the liner projection, thus increasing the fire ring crush. Use these spacer plates to compensate for low liner projections that are less then 0.076 mm (0.003 in) or if the inspection of the top deck reveals no measurable damage directly under the liner flanges, but the average liner projection is less than 0.076 mm (0.003 in).
NOTE: Do not exceed the maximum liner projection of 0.152 mm (0.006 in). Excessive liner projection will contribute to liner flange cracking.
5. If a liner does not measure within the correct projection specifications, the projection can be changed with a counterbore operation to the top surface of the cylinder block. The counterbore depth must be in a range from a minimum of 0.76mm (0.030 in) to a maximum of 5.260 mm (0.2071 in). Shims are available to then adjust the liner to the correct projection.
NOTE: See Special Instruction, for procedure to use the 8S-3140 Cylinder Block Counter Boring Tool Arrangement. See the topic, "Cylinder Liner Projection" in Systems Operation Testing & Adjusting Module for more information.
6. Put a mark on cylinder liners (1) and the spacer plate so the cylinder liners can be installed in the same position when the proper liner projection is established.
7. Put liquid soap on seals (3) (if the seals are black in color), the grooves of the liner and on the bore in the block. Put clean engine oil on seals (3) (if the seals are blue or brown in color), the grooves of the liner and on the bore in the block. Install seals (3) on the cylinder liner. Put filler band (4) in clean SAE 30 Oil for a moment. Install filler band (4) on the cylinder liner.
NOTE: After the filler band is installed on the cylinder liner, the cylinder liner must be installed immediately into the cylinder block or the filler band might swell and be pinched under the liner during installation.
8. Use Tool (B) to install cylinder liner (1) in the block. Make sure the mark on the cylinder liner is in alignment with the mark on the spacer plate.
NOTE: For more detailed information regarding the cylinder liners, see the topic "Cylinder Liners" in the Specifications Module.
End By:
a. install pistons
b. install spacer plate