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G3612 and G3616 Engines Caterpillar | Spare parts

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Basic Block... G3612 and G3616 Engines Caterpillar

Usage:
G3612 1YG G3612 1YG G3606 3XF G3606 3XF G3616 4CG G3616 4CG G3608 4WF G3608 4WF G3606B 4ZS G3608 BEN
G3612 BKE G3616 BLB

Connecting Rod Bearings

The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are fretted, check the bore size. Fretting can be an indication
of wear because of a loose fit.

Connecting rod bearings are available with 0.50 mm (.020 inch) and 1.00 mm (.040 inch) smaller inside diameter than the original size
bearing. These bearings are for crankshafts that have been ground.

Main Bearings
Main bearings are available with a larger outside diameter than the original size bearings. These bearings are available for the cylinder blocks
with the main bearing bore that is larger than the original size.

Main bearings are available with 0.50 mm (0.020 inch), 1.00 mm (0.040 inch), and 2.0 mm (0.080 inch) larger outside diameter than the
original bearing.

The main bearings are also available with a 0.25 mm (0.010 inch) and 1.00 mm (0.040 inch) smaller inside diameter than the standard
bearing. Main bearings are also available with smaller inside diameter of 0.50 mm (0.020 inch).

Cylinder Block
If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold
the caps to the torque that is shown in the Specifications. Alignment error in the bores must not be more than 0.040 mm (.0016 inch). Refer to
the Special Instruction, SMHS7606 for the use of the 1P-4000 Line Boring Tool Group for the alignment of the main bearing bores. The 1P-
3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.

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Illustration 1 g00285686

1P-3537 Dial Bore Gauge Group

Flywheel and Flywheel Housing

Table 1
Tools Needed Quantity

8T-5096 Dial Indicator Group 1

Face Runout (Axial Eccentricity) of the Flywheel Housing

Illustration 2 g00285931

8T-5096 Dial Indicator Group

If you use any other method of checking the face runout, remember that the bearing clearance must be removed. Remove the clearance in
order to get the correct measurements.

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel housing/">housing.

2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

Illustration 3 g00285932

Checking face runout of the flywheel housing

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NOTICE
The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing
surfaces.

3. Turn the flywheel while the dial indicator is set at 0.0 mm (.00 inch) at location (A). Read the dial indicator at locations (B), (C, and) (D) .

4. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more
than 0.38 mm (.015 inch), which is the maximum permissible face runout (axial eccentricity) of the flywheel housing/">housing.

Bore Runout (Radial Eccentricity) of the Flywheel Housing

Illustration 4 g00285934

8T-5096 Dial Indicator

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the flywheel housing/">housing.

Illustration 5 g00285936

2. While the dial indicator is in the position at location (C), adjust the dial indicator to 0.0 mm (.00 inch). Push the crankshaft upward
against the top of the bearing. Refer to the illustration 5. Write the measurement for bearing clearance on line 1 in column (C) .
Note: Write the measurements for the dial indicator with the correct notations. This notation is necessary for making the calculations in
the chart correctly.

3. Divide the measurement from Step 2 by two. Write this number on line 1 in columns (B) and (D) .

NOTICE

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The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing
surfaces.

4. Turn the flywheel in order to put the dial indicator at (A). Adjust the dial indicator to 0.0 mm (.00 inch).

Illustration 6 g00285932

Checking bore runout of the flywheel housing

5. Turn the flywheel counterclockwise in order to put the dial indicator at (B). Write the measurements in the chart.

6. Turn the flywheel counterclockwise in order to put the dial indicator at (C). Write the measurement in the chart.

7. Turn the flywheel counterclockwise in order to put the dial indicator at (D). Write the measurement in the chart.

8. Add the lines together in each column.

9. Subtract the smaller number from the larger number in column B and column D. Place this number on line III. The result is the horizontal
eccentricity (out of round). Line III in column C is the vertical eccentricity.

Illustration 7 g00286046

Graph for total eccentricity

(1) Total vertical eccentricity

(2) Total horizontal eccentricity

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(3) Acceptable value

(4) Unacceptable value

10. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

11. If the point of intersection is in the range marked "Acceptable", the bore is in alignment. If the point of intersection is in the range marked
"Not acceptable", the flywheel housing must be changed.

Face Runout (Axial Eccentricity) of the Flywheel

Illustration 8 g00286049

Checking face runout of the flywheel

1. Refer to illustration 8 and install the dial indicator. Always put a force on the crankshaft in the same direction before the dial indicator is
read. The force will remove any crankshaft end clearance.

2. Set the dial indicator to read 0.0 mm (.00 inch).

NOTICE
The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing
surfaces.

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This
value must not exceed the maximum permissible face runout (axial eccentricity) of the flywheel.

Bore Runout (Radial Eccentricity) of the Flywheel

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Illustration 9 g00286054

Checking bore runout of the flywheel

(1) 7H-1945 Holding Rod

(2) 7H-1645 Holding Rod

(3) 7H-1942 Dial Indicator

(4) 7H-1940 Universal Attachment

1. Install the 7H-1942 Dial Indicator (3). Make an adjustment of the 7H-1940 Universal Attachment (4) so that the dial indicator makes
contact on the flywheel.

2. Set the dial indicator to read 0.0 mm (.00 inch).

NOTICE
The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing
surfaces.

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This
value must not exceed the maximum permissible bore runout (radial eccentricity) of the flywheel.

Illustration 10 g00286058

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Flywheel clutch pilot bearing bore

5. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This
value must not exceed the maximum permissible pilot bore runout of the flywheel.

Checking Crankshaft Deflection (Bend)

The crankshaft can be deflected if the engine was not installed correctly. If the engine mounting rail is not fastened correctly to the foundation
mounting rail, the cylinder block can twist or the cylinder block can bend. The deformation will cause the crankshaft to deflect. This deflection
can cause crankshaft failure and bearing failure.

The crankshaft deflection must be checked after the final installation of the engine. The following procedure can be used to check the
crankshaft deflection.

1. Remove an inspection cover from the cylinder block that will give access to the connecting rod journal. This inspection cover should be
nearest to the center of the engine. This check must be made at the center connecting rod journals.

NOTICE
The engine must be prelubed before the crankshaft is rotated. Damage can result if the crankshaft is rotated on dry bearing
surfaces.

2. Turn the crankshaft in the direction of normal rotation until the center of the counterweights barely go beyond the connecting rod.

3. When the counterweight is not available on both sides, install a 2B-7218 Bolt with a 1B-4333 Nut or 2J-3507 Full Nut in the crankshaft.
Tighten the nut against the crankshaft. The bolt and the nut are used to provide a locating face.

4. Install a Starrett Crankshaft Distortion Dial Gauge No. 696 with a Starrett No. 696B between the bolt and the counterweight. Put the dial
indicator within 10 mm (.39 inch) of the end of the counterweight. Turn the dial of the dial indicator in order to align the zero with the
pointer. Turn the dial indicator on the end points until the pointer of the dial indicator will not move from zero.

5. Turn the crankshaft in the direction of the normal rotation until the dial indicator almost contacts the connecting rod. This connecting rod
is on the other side of the crankshaft.
Note: Do not allow the dial indicator to contact the connecting rod.

6. The dial indicator reading must not change more than 0.080 mm (.0032 inch) for the approximate 300 degrees of crankshaft rotation.
Now turn the crankshaft in the opposite direction to the starting position. The dial indicator must now read zero. If the dial indicator does
not read zero, do the procedure again.

If the dial indicator read more than 0.080 mm (.0032 inch), the cylinder block is distorted. Loosen the bolts that hold the engine mounting rails
to the foundation mounting rails. Adjust the shims in order to make the engine straight again. Ensure sufficient clearance for the engine
mounting bolts in order to allow the engine to expand as the engine gets hot.

Engine Alignment
Engine alignment with the driven equipment should be checked at scheduled maintenance intervals. Refer to the engine Operation and
Maintenance Manual .

Refer to the following alignment specifications:

Crankshaft end play ... 0.40 0.20 mm (0.016 0.008 inch)

Maximum allowable softfoot ... 0.08 mm (0.0031 inch)

Maximum allowable parallel offset or bore offset ... 0.127 mm (0.0050 inch)

Maximum allowable axial offset or face offset ... 0.178 mm (0.0070 inch)

Maintain proper tension on the engine mounting feet to base bolts at all times. The torque must be checked every 1000 hours. Refer to
following service manuals for more information: Special Instruction, REHS0423, "Alignment Of Two-Bearing Generators", Application &
Installation Guide, LEBW4975, "Alignment" and Application & Installation Guide, LEBW4974, "Mounting".

Vibration Damper
Damage to the damper or failure of the damper will increase vibrations. The vibration will result in damage to the crankshaft.

Replace the damper if the damper is bent or damaged. Replace the damper if the bolt holes are oversize. Replacement of the damper is also
needed at the time of a crankshaft failure due to torsional forces.

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