GEAR-INPUT SUN 3G6239 - Caterpillar

start by:a) remove pistons1. Drain the coolant from the cylinder block.2. Put covers on the crankshaft journals for protection from dirt and water. 3. Remove cylinder liners with tooling (A). 4. Remove seals (1) and filler band (2) from each liner.Install Cylinder Liners
1. Clean the cylinder liners and liner bores in the block.2. Install the liners in the block without seals or bands.3. Check the cylinder liner (projection) height as follows: a) Install four bolts and washers (3) from tooling (A) around each cylinder liner as shown. Tighten the bolts evenly to a torque of 70 lb.ft. (95 N m).b) Install bar (4), plate (5), plates (2), bolts (1) and washers from tooling (A). Be sure the bar is in position at the center of the liner and the liner surface is clean. Tighten bolts (1) evenly to a torque of 50 lb.ft. (70 N m).c) Check the distance from the bottom edge of bar (4) to the top edge of the spacer plate. The distance on each end of the bar must be the same.d) Check the liner (projection) height with tool (B) at four locations around the liner. Liner (projection) height must be .005 .003 in. (0.13 0.08 mm). The difference between the four measurements on the same liner must not be more than .002 in. (0.05 mm). The difference between liner (projection) height for liners next to each other must not be more than .002 in. (0.05 mm). If the liner is turned in the cylinder block it can make a difference in liner (projection) height. 4. If the liner (projection) height is not .005 .003 in. (0.13 0.08 mm), check the thickness of the following parts:a) Spacer plate (X): .338 .001 in. (8.59 0.03 mm).b) Spacer gasket (Y): .008 .001 in. (0.20 0.03 mm). All surfaces must be clean and dry when the gasket is installed.c) Cylinder liner flange (Z): .350 .0008 in. (8.890 0.020 mm). The cylinder liner (projection) height can be changed by the adjustment of a counterbore in the block. See SPECIAL INSTRUCTIONS, FORM FM055228. Shims are available for the adjustment of the liner (projection) height. See PROJECTION OF CYLINDER LINER in TESTING AND ADJUSTING for the shim thickness and part number.5. Put a mark on the cylinder liners and block so the liners can be installed in the same position.6. Remove tooling (A) and tool (B). Remove one liner.7. Put liquid soap on seals (6), grooves of the liner and the bore of the block.8. Put filler band (5) in clean SAE 30 oil for a short moment. Install the filler band on the liner. 9. Install the liner immediately after the filler band is installed. Make sure the mark on the liner is in alignment with the mark on the block. Use tooling (C) to push the liner into position.10. Do Steps 6 through 9 for the remainder of the liners.end by:a) install pistons