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    Liners

    Uploaded by

    jengandxb
    This document provides instructions for measuring, installing, and checking the protrusion of cylinder liners in an engine. Key steps include measuring the inside diameter of new liners, applying a bead of sealant to the cylinder block counterbore surface, installing various seals and shims, and using a tool to push the liner into place until its flange touches the counterbore ring. The document specifies torque values and refers to other procedures for additional details.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Liners

    Uploaded by

    jengandxb
    319 views4 pages
    This document provides instructions for measuring, installing, and checking the protrusion of cylinder liners in an engine. Key steps include measuring the inside diameter of new liners, applying a bead of sealant to the cylinder block counterbore surface, installing various seals and shims, and using a tool to push the liner into place until its flange touches the counterbore ring. The document specifies torque values and refers to other procedures for additional details.

    Original Description:

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    This document provides instructions for measuring, installing, and checking the protrusion of cylinder liners in an engine. Key steps include measuring the inside diameter of new liners, applying a bead of sealant to the cylinder block counterbore surface, installing various seals and shims, and using a tool to push the liner into place until its flange touches the counterbore ring. The document specifies torque values and refers to other procedures for additional details.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    319 views4 pages

    Liners

    Uploaded by

    jengandxb
    This document provides instructions for measuring, installing, and checking the protrusion of cylinder liners in an engine. Key steps include measuring the inside diameter of new liners, applying a bead of sealant to the cylinder block counterbore surface, installing various seals and shims, and using a tool to push the liner into place until its flange touches the counterbore ring. The document specifies torque values and refers to other procedures for additional details.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    At a glance
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    The document outlines the procedure for measuring cylinder liner dimensions and installing cylinder liners.

    To measure cylinder liner protrusion, you must install various components like the push plate and push screw and turn the push screw until the bottom of the liner flange touches the counterbore ring.

    To install cylinder liner seals, you must lubricate components, install seals like the crevice seal and D-rings in the correct orientation, and apply a bead of gasket sealant to the cylinder block counterbore surface.

    3/7/2019 QuickServe Online | (4021528) GTA38, K38, K50, QSK38, and QSK50 Service Manual

    (/qs3/pubsys2/xml/en/manual/4021528/4021528-titlepage.html)

    Measure
    Note : New cylinder liners can be 0.005 mm to 0.015
    mm [0.0002 in to 0.0006 in] smaller than the minimum
    specification because of the Lubrite coating.
    Use a dial bore gauge. Measure the inside diameter of the liner
    at the:
    Top
    Bottom
    Middle.
    Take two measurements at each location. The measurements
    must be 90 degrees apart.

    Cylinder Liner Inside Diameter (New)


    mm in
    158.737 MIN 6.2495
    158.877 MAX 6.2550

    The inside diameter must be no more than 0.076 mm [0.003


    in] out-of-round at the top two measurement locations, and no
    more than 0.05 mm [0.002 in] out-of-round in the bottom
    measurement location.
    If the inside diameter is not within specifications at any of the
    three locations, the liner must be removed. Check for a twisted
    o-ring or an out-of-round liner.
    A new bead of sealant must be applied if the liner is removed
    and installed again.
    Use the following procedure for instructions on how to measure
    cylinder liner protrusion. Refer to Procedure 001-064 in Section
    1. (/qs3/pubsys2/xml/en/procedures/28/28-001-064-tr.html)

    https://quickserve.cummins.com/qs3/portal/service/manual/en/4021528/ 1/4
    3/7/2019 QuickServe Online | (4021528) GTA38, K38, K50, QSK38, and QSK50 Service Manual

    Install
    Lubricate the packing ring bores of the cylinder block with
    vegetable oil.

     WARNING 
    Do not use starting fluid. Naptha and methyl ketone are
    highly flammable and explosive. Follow the instructions
    of the manufacturer.

    Use a hydrocarbon solvent, such as naptha, methyl ethyl


    ketone, tricholorethane 1,1,1 (methyl chloroform), or equivalent
    to clean the counterbore.
    Note : The counterbore ledge must be dry. The sealant
    applied in assembly will not dry if there is oil on the
    ledge.

    Note : The counterbore ledge must be dry. The sealant


    applied in assembly will not dry if there is oil on the
    ledge.
    Install the shims (1) if required. The following table lists the part
    numbers and thicknesses.

    Shims with Tabs


    Part Number of
    mm in
    Number Notches
    3088385 0.46 0.018 two
    3088386 0.52 0.0205 two
    3088387 0.56 0.022 two
    3088388 0.79 0.031 two

    https://quickserve.cummins.com/qs3/portal/service/manual/en/4021528/ 2/4
    3/7/2019 QuickServe Online | (4021528) GTA38, K38, K50, QSK38, and QSK50 Service Manual

    Due to the interference fit of the shims with tabs, it is


    necessary to keep the shim straight on the liner and push with
    your fingers near the tabs to work down over the lower press fit
    diameter. Do not push on the shim too hard or the tabs can be
    deformed to the point that the seal will not fit squarely on the
    bottom of the liner flange. The thickest seal rings can deform to
    a very slight angle during installation on the liner. Some
    deformation is acceptable, as long as the tabs will still engage
    the radius under the liner flange.
    Note : Do not lubricate the crevice seal and the d-ring
    seals or shims. This prevents oil transfer to the cylinder
    counterbore ledge during assembly.
    The packing ring bore must be lubricated thoroughly.
    Note : A new rectangular crevice seal was introduced in
    September 1994, ESN first 33128708), manufactured
    from nitrile material and provides improved durability
    and increased resistance to nibbling and erosion.
    The beveled edge of the crevice seal (2) must be positioned
    as illustrated. Install the crevice seal.
    Note : The ring seals have a d-shaped cross section.
    This type of ring seal must be installed with the flat side
    against the cylinder liner.
    Install the D-ring seals as shown. Use the mold mark on the
    seals to check if the seal is twisted.
    Black D-ring (3)
    Red D-ring (4).

     CAUTION 
    The parts must be installed within 5 minutes after
    applying the sealant. An excessive amount of sealant can
    cause engine damage.

    Install a bead of gasket sealant, Part Number 3823494, or


    equivalent, 1.1 to 1.6 mm [0.0468 to 0.0625 in] wide onto the
    cylinder block counterbore surface.

    The sealant bead must be a continuous loop and must not


    contain any breaks or voids from start to finish.

    Make sure that the end of the bead overlaps the beginning of
    the bead, approximately 6.0 mm [0.24 in].

    https://quickserve.cummins.com/qs3/portal/service/manual/en/4021528/ 3/4
    3/7/2019 QuickServe Online | (4021528) GTA38, K38, K50, QSK38, and QSK50 Service Manual

    Note : The sealant does not change the cylinder liner


    protrusion measurement. It prevents coolant leaks. The
    sealant fills the small spaces between the liner flange
    and the counterbore ring and block.
    The counterbore ring must be positioned with the curved edge
    as illustrated. Install the counterbore ring (5).

    Push the liner in the block by hand.

    Use the liner installation tool, Part Number 3375422, or


    equivalent. Install the bridge assembly. Install two cylinder
    head capscrews.
    Torque Value: 47 n•m [ 35 ft-lb ]
    Install the push plate. Make sure the plate is aligned on the
    cylinder liner. Turn the push screw until it touches the push
    plate.

    Use a wrench. Do not apply more than 68 N•m [50 ft-lb] of


    torque. Turn the push screw until the bottom of the liner flange
    touches the counterbore ring.

    Remove the tool.

    Check the liner protrusion. Use the following procedure for


    instructions on how to measure liner protrusion. Refer to
    Procedure 001-064 in Section 1.
    (/qs3/pubsys2/xml/en/procedures/28/28-001-064-tr.html)

    Last Modified: 01-Jun-2017

    https://quickserve.cummins.com/qs3/portal/service/manual/en/4021528/ 4/4

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