BODY- 4495904 - Caterpillar

Record the maximum measurement and the minimum measurement for each cylinder in Table 3. Subtract the minimum measurement from the maximum measurement in order to determine the maximum variation for each cylinder liner projection.
Table 3
Maximum Variation for Each Cylinder
Cylinder 1 (maximum)
Cylinder 1 (minimum)
Variation
Cylinder 2 (maximum)
Cylinder 2 (minimum)
Variation
Cylinder 3 (maximum)
Cylinder 3 (minimum)
Variation
Cylinder 4 (maximum)
Cylinder 4 (minimum)
Variation
Cylinder 5 (maximum)
Cylinder 5 (minimum)
Variation
Cylinder 6 (maximum)
Cylinder 6 (minimum)
Variation
Cylinder 7 (maximum)
Cylinder 7 (minimum)
Variation
Cylinder 8 (maximum)
Cylinder 8 (minimum)
Variation
Cylinder 9 (maximum)
Cylinder 9 (minimum)
Variation
Cylinder 10 (maximum)
Cylinder 10 (minimum)
Variation
Cylinder 11 (maximum)
Cylinder 11 (minimum)
Variation
Cylinder 12 (maximum)
Cylinder 12 (minimum)
Variation
Record the average measurement for the adjacent cylinder liners in Table 4. Determine the variation between the adjacent cylinder liners. Record the variations in Table 4.
Table 4
Variation of the Average Measurements for Adjacent Cylinder Liners
Cylinder 1 (average)
Cylinder 2 (average)
Variation
Cylinder 2 (average)
Cylinder 3 (average)
Variation
Cylinder 3 (average)
Cylinder 4 (average)
Variation
Cylinder 4 (average)
Cylinder 5 (average)
Variation
Cylinder 5 (average)
Cylinder 6 (average)
Variation
Cylinder 7 (average)
Cylinder 8 (average)
Variation
Cylinder 8 (average)
Cylinder 9 (average)
Variation
Cylinder 9 (average)
Cylinder 10 (average)
Variation
Cylinder 10 (average)
Cylinder 11 (average)
Variation
Cylinder 11 (average)
Cylinder 12 (average)
Variation
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.
Table 5
Maximum Variation of All of the Cylinder Liner Projections
Greatest average measurement
Least average measurement
Variation
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 0.05 mm (0.002 inch)
Maximum average variation between adjacent cylinder liners 0.05 mm (0.002 inch)
Maximum variation for all of the cylinder liners 0.10 mm (0.004 inch) Result 1The 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 2One 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 any of the following shims in order to obtain the correct cylinder liner projection: 8S-6045 Shim ( 0.18 mm (0.007 inch)), 8S-6046 Shim ( 0.20 mm (0.008 inch)), 8S-6047 Shim ( 0.23 mm (0.009 inch)), 8S-6048 Shim ( 0.38 mm (0.015 inch)) and 8S-6049 Shim ( 0.76 mm (0.030 inch)).
Obtain new cylinder liners.
Obtain a new engine block.Result 3One 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