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Product: GENERATOR SET

Model: G3512E GENERATOR SET SSR
Configuration: G3512E Generator Set SSR00001-UP

Engine News
2013/09/12
Media Number -SEBD9896-00 Publication Date -12/09/2013 Date Updated -12/09/2013

i05438601

Calculating Cylinder Liner Projection for 3500, 3500B, 3500C,

and G3500 Engines {1201, 1216}
SMCS - 1201-E5; 1216

Caterpillar Products:
3500 Family Generator Sets and Power Modules
3500C Engines
G3500 Family Generator Sets and Power Modules
Engine: Commercial
3500 and 3500B
G3500 Family

Engine News SEBD9892, 21 August 2013, "Calculating Cylinder Liner Projection for 3500, 3500B,
3500C, and G3500 Engines". Disregard the previous article. Table two has been updated.

Measuring Wear of the Cylinder Block at the Cylinder Liner

Contact Surface

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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 Special Instruction, REHS7133, "Installation of the Cylinder
Liner 353-5617 Insert and 353-5618 Insert for 3500 and G3500 Engines".

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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 rebuild

Note: 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 Gasket

A 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.

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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

1. 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.

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Illustration 4 g02657156

2. Use tool (B) to measure the thickness of the spacer plate at the four locations identified by "X"
in Illustration 4. Determine the average of the measurements.

The result is measurement (X). Mark the result on the spacer plate with a permanent marker. Do
not scribe the material.

3. Compare the average measurements to the dimensions listed in Table 2.

If the average measured dimensions are within the acceptable range, the parts can be installed.

If the average measured dimensions are not within the acceptable range, the parts cannot be
installed. New parts must be obtained.

Note: There is no need to measure the thickness of the 144-5692 Plate Gasket because a new
gasket is always installed. The nominal manufacturing dimension is used in the calculation.

Note: Reference Test and Adjusting, UENR0519, "Cylinder Liner Projection"

Table 2
Dimensions for Acceptable Cylinder Liner Projection with the 110-6991 Cylinder Head
Gasket
Part Dimension Value

211-7826 Cylinder Block Liner flange

12.65 0.02 mm (0.498 0.0001 inch) Z

110-6994 Spacer Plate X

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12.31 0.03 mm (0.4846 0.0012 inch)

362-9677 Spacer Plate 12.33 0.03 mm (0.4854 0.0012 inch) X

144-5692 Plate Gasket Y

0.21 0.03 mm (0.008 0.001 inch)

Allowable projection 0.06 mm (0.002 inch) to

0.20 mm (0.008 inch)

Note: The allowable projection is based on statistical tolerancing.

Note: Any spacer plates and cylinder liners that are within the acceptable ranges may be
interchanged with other spacer plates and cylinder liners in order to meet the allowable
projection. For example, a cylinder liner flange with the thickest acceptable dimension mated
with a spacer plate with the thinnest acceptable dimension may not meet the allowable
projection. In that case, a different cylinder liner or spacer plate may be substituted.

Table 3 is an example of the calculation for cylinder liner projection. The resulting difference of 0.13
mm is within the range of 0.103 to 0.171 mm. The calculated projection in the example is acceptable.

Table 3
Example of the Calculation for Cylinder Liner Projection
Cylinder Liner Projection = Z - X - Y
Value
Measurement Dimension

Average thickness of the 211-7826 Cylinder Block

Z
Liner flange 12.65 mm (0.4980 inch)

Average thickness of the 110-6994 Spacer Plate X

-12.31mm (-0.4854 inch)

362-9677 Spacer Plate 12.33 0.03 mm (0.4854 X

0.0012 inch)

Nominal thickness of the 144-5692 Plate Gasket Y

-0.21 mm (-0.008 inch)

Calculated projection
0.13 mm (0.0051 inch)

Refer to the engine Disassembly and Assembly manual to make sure that the cylinder liner is properly
installed.

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