DISC (OUTER) 2A4444 - Caterpillar

Caterpillar Products 3500 Family Generator Sets and Power Modules 3500C Engines G3500 Family Generator Sets and Power ModulesEngine Commercial 3500 and 3500B G3500 FamilyEngine Commercial 3500 and 3500B G3500 FamilyEngine News, SEBD9896, 12, September 2013, "Calculating Cylinder Liner Projection for 3500, 3500B, 3500C, and G3500 Engines". Disregard the previous article.Measuring Wear of the Cylinder Block at the Cylinder Liner Contact Surface
Illustration 1 g02657157
Points at which to measure the depth of the wear around the circumference of the cylinder bore
Illustration 2 g02658239
Using tool (A) to measure the depth of the wear in the cylinder block under the cylinder liner flange
Use tool (A) to measure the depth of the wear in the cylinder block in the area under the cylinder liner flange. Take measurements at the eight points that are identified in Illustration 1. Illustration 2 demonstrates proper placement of the dial indicator between the tapped hole and the cylinder bore.If the depth of the wear under the cylinder liner flange is greater than 0.013 mm (0.0005 inch), the block must be salvaged according to Reuse And Salvage Guidelines, SEBF8255, "Procedure to Salvage Top Decks of Cylinder Blocks of 3500 Engines".Calculating Cylinder Liner Projection
The following method for calculating the liner projection is the preferred method under these circumstances:
Single cylinder head joint repair
Engine rebuildNote: When installation of spare used spacer plates and cylinder liners is desired, having the stocked parts measured and matched will reduce repair time.Note: The method of measuring liner projection that uses the 8T-0455 Liner Projection Tool Group can still be used.Regardless of the procedure, the contact surface of the cylinder block for the liner flange and spacer plate must be thoroughly clean before installation of replacement parts.If a new spacer plate and cylinder liner will be installed in the same cylinder, there is no need to calculate the cylinder liner projection. The production process control for the parts is adequate.If a used spacer plate or cylinder liner will be installed, perform the following measurement and calculation procedure.
Table 1
Required Tools
A 8T-0455 Liner Projection Tool Group
B Digital micrometer with a resolution of 0.001 mm The cylinder liner projection is now a calculation based on measurement of parts that uses the following dimensions:
The average thickness of the flange for the 211-7826 Cylinder Block Liner, measured in four places
The average thickness of the 110-6994 Spacer Plate, measured in four places
The nominal manufactured thickness of a new 144-5692 Plate GasketA new 144-5692 Plate Gasket must be installed with the spacer plate and cylinder liner.Use the following procedure to calculate the cylinder liner projection.
Illustration 3 g02657236
(X) Average thickness of the spacer plate
(Y) Nominal thickness of the spacer plate gasket
(Z) Average thickness of the cylinder liner flange
Use tool (B) to measure the thickness of the cylinder liner flange at four equally spaced locations around the circumference of the flange. Determine the average of the measurements.The result is dimension (Z). Mark the result on the cylinder liner with a permanent marker. Do not scribe the material.
Illustration 4 g02657156
Use tool (B) to measure the thickness of the spacer