Installation Of 5P6595 Insert For Cylinder Liner Seat{1217} Caterpillar

The 5P6595 Insert (1) can be used for the repair of cracks in the seat for cylinder liners of the above engines, when the cracks are too large for repair with the 5P1625 Insert. The new insert is larger in diameter and has a design that will put any stress over the main walls of the cylinder block. This will help to prevent any more cracks in this area.

Tools Needed

Parts of the 5P1618 Tool Arrangement and other additional tools are needed in the installation procedure of the cylinder liner seat inserts. Tools needed are given below.

Drive Assembly Maintenance

(1) Assemble tool holder (1) on boring tool (2). Make sure the tool holder slot is down and both the pilot on the boring tool and the pilot on the tool holder are clean. Install the washer and nut. Tighten nut (3) to 50 ± 5 lb.ft. (70 ± 7) torque.

(2) With the boring tool in the horizontal position, remove plug (4) and check the oil level in the hydraulic feed unit. Fill the unit with SAE10W, 20W, or 30W oil. Install plug (4). Loosen knob (5) to release the feed control valve and move tool holder (1) in and out several times. Remove plug (4) and again check the oil level. Fill with oil if necessary and again install plug (4). Tighten knob (5).

NOTE: If the oil level is low, the tool will not cut smoothly.

(3) Check the adjustment of 6V4984 Ball Spring Screw (6). To make an adjustment, tighten screw (6) until it is tight, then loosen it 1/4 turn. If it is still difficult to install a cutting tool, inspect screw (6). It is possible that screw (6) is worn and a replacement screw is needed. It is also possible that 6V4985 Cutter Holder Plate (7) is worn and is the cause of tool drag. Inspect the inside of holder plate (7) and install a new holder plate if necessary.

Installation Of The Boring Tool On A Cylinder Block

NOTE: All studs and dowel pins on the top surface of the cylinder block, in the area around each cylinder liner bore, must be removed so there will be enough room to install the boring tool group and make the counterbore needed for insert installation. Use a 2P5535 Stud Remover Group, 8S1378 Stud Remover Group and the 5P944 Dowel Puller Group for stud and dowel removal.

(1) Use a file to remove any rough places from the top surface of the cylinder block. Clean the top of the cylinder block to make it free from all foreign material. Also make sure the cylinder liner pilot bore is clean and free from all foreign material. This is necessary because the boring tool uses this area for alignment.

NOTE: If it is necessary to do any surface grinding on the cylinder block top surface, do it before a counterbore cut is made. Any grinding on the top of the cylinder block after the inserts are installed, can cause the inserts to "pull-up" out of the counterbore seats.

(2) Install the boring tool on the cylinder block. Release the feed control valve by turning knob (1) counterclockwise; the tool holder will then move down into the cylinder liner pilot bore.

(3) Make an adjustment to nut (2) until tool holder (3) is engaged in the pilot bore approximately .25" (6.4) as shown.

(4) Tighten screw (4) to hold nut (5) in place. Use four bolts (6) with 5P1769 Washers (7) to fasten the boring tool to the cylinder block. Tighten bolts (6) just enough to hold the boring tool in position, yet loose enough to let the boring tool be moved if necessary. While the tool holder is turned manually with nut (5), tighten bolts (6) to a torque of 50 ± 5 lb.ft. (70 ± 7). The tool holder must turn freely after all bolts (6) have been tightened.

(5) Manually pull the tool holder up out of the cylinder liner bore. Turn knob (1) clockwise to close the feed control valve.

Make The Cut For The First Counterbore

(1) Put cutter (1) into micrometer fixture (2) and adjust the cutter to 7.000" (177.8).

(2) Clean tool holder slot (A) before installing the cutting tool. Install cutter (1) into slot (A). Pull cutter (1) out approximately .12" (3.2) over the top face of the cylinder block, while the setting for the depth of cut is made. Tighten screw (3). Carefully loosen knob (4) to lower the boring bar until cutter (1) is against the top face of the cylinder block.

(3) Loosen screw (5) until adjusting nut (6) is free. Install both pieces of 6V157 Depth Gauge (7) .894" (22.71) and make an adjustment to nut (6) until it is against gauge (7). Tighten screw (5), to hold nut (6) in place. Remove depth gauge (7).

(4) Turn knob (4) counterclockwise and lift the cutter so it is above the top face (B) of the cylinder block. Turn knob (4) clockwise to hold the toolholder in position. Loosen screw (3) and push the cutter tool into tool holder slot (A) as far as it will go, then tighten screw (3). Loosen knob (4) and lower cutter (1) until it is .06" (1.5) above the liner seat. Tighten knob (4).

(5) Use a heavy duty industrial drill and adapter (8) to operate the boring tool. Remove the depth gauge and start the rough cut.

(6) Stop the cutter rotation immediately when adjusting nut (6) is against positive stop (9). Loosen knob (4).

(7) Lift the cutter out of the cylinder block and tighten knob (4) again. Loosen screw (3) and remove cutter (1) with 5P1656 Hook (10).

(8) Use fine emery paper to remove any burrs from top face (B) of the cylinder block.

(9) Check the bottom of the counterbore to see if it is smooth. It may be necessary to turn the boring tool very slowly for several revolutions to get a smooth finish on the bottom of the counterbore.

NOTE: The depth of the counterbore can be checked with depth micrometer (11). The correct dimension is .894" (22.71).

(10) It is now necessary to make two more rough cuts, one at a time. Adjust the cutter to 7.200" (182.9) and do steps 1 through 7. Then adjust the cutter to 7.400" (187.9) and do steps 1 through 7.

(11) Put the 5P6594 Master Gauge (12) 7.550" (191.8) into micrometer fixture (2); make sure the side having the mark, UP, is on top. Make an adjustment to micrometer (2) until the micrometer stem is against the master gauge. The micrometer should then read the same as the dimension given on the side of master gauge (12).

(12) Remove the master gauge and put cutter (1) into micrometer fixture (2). Make an adjustment to cutter (1) until it is the exact same size as the master gauge.

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NOTICE
Be careful not to loosen screw (C) too fast, because the adjustment of cutter (1) has a spring load behind it and damage may be caused to the cutting edge.

(13) Clean the tool holder slot carefully before installing the cutting tool. Install cutter (1) into the slot, and push the tool back into the slot as far as it will go. Tighten screw (3). Lower cutter (1) until it is .06" (1.5) above the top face of the cylinder block. Close the feed control valve by turning knob (4). Start the finish cut of 7.550" (191.8).

(14) Make the complete finish cut without stopping. Stop the cutter rotation immediately when adjusting nut (6) is against positive stop (9).

(15) Loosen knob (4). Lift the cutter out of the cylinder block and tighten knob (4) again. Loosen screw (3) and remove cutter (1) with 5P1656 Hook (10).

Make The Cut For The Second Counterbore

(1) Put cutter (1) into micrometer fixture (2). Adjust cutter (1) to 7.650" (194.3).

(2) Install both pieces of 6V156 Depth Gauge (3) .354" (8.99).

NOTE: Depth gauge (3) must be kept in this location for the remainder of the counterbore work.

(3) Clean the tool holder slot carefully before installing the cutting tool. Install cutter (1) into the slot, and push the tool back into the slot as far as it will go. Tighten screw (4). Lower cutter (1) until it is .06" (1.5) above the top face of the cylinder block. Close the feed control valve.

(4) Use the heavy duty industrial drill and adapter (5) to operate the boring tool. Make the rough cut of 7.650" (194.3).

(5) Stop the cutter rotation immediately when adjusting nut (6) is against positive stop (7). Loosen knob (8).

(6) Lift the cutter out of the cylinder block and tighten knob (8) again. Loosen screw (4) and remove cutter (1) with 5P1656 Hook (9).

(7) Put 5P6593 Master Gauge (10) 7.7500" (196.9) into micrometer fixture (2); make sure the side having the mark, UP, is on top. Make an adjustment to micrometer (2) until the micrometer stem is against the master gauge. The micrometer should then read the same as the dimension given on the side of master gauge (10).

(8) Remove the master gauge and put cutter (1) into micrometer fixture (2). Make an adjustment to cutter (1) until it is the exact same size as the master gauge.

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NOTICE
Be careful not to loosen screw (C) too fast, because the adjustment of cutter (1) has a spring load behind it and damage may be caused to the cutting edge.

(9) Clean the tool holder slot carefully before installing the cutting tool. Install cutter (1) into the slot, and push the tool back into the slot as far as it will go. Tighten screw (4). Lower cutter (1) until it is .06" (1.5) above the top face of the cylinder block. Close the feed control valve by turning knob (8). Start the finish cut of 7.7500" (196.9).

(10) Make the complete finish cut without stopping. Stop the cutter rotation immediately when adjusting nut (6) is against positive stop (7). Use fine emery paper as shown, to remove any burrs from top face (B) of the cylinder block.

(11) Check the bottom of the counterbore to see if it is smooth. It may be necessary to turn the boring tool slowly, for several revolutions to get a smooth finish on the bottom of the counterbore.

NOTE: The depth of the counterbore can be checked with depth micrometer (11). The correct dimension is .540" (13.72).

(12) Use emery paper to remove all sharp edges. Use a small file to remove any sharp edges that can break off around the three stud holes. Use a 5/8"-11 thread tap in stud holes (D) to clean the threads. Thoroughly clean both counterbores and the stud holes.

Installation Of 5P6595 Insert

Tools needed to install a 5P6595 Insert are: (1) 6V164 Insert Installer, (2) 6V4987 Guide Plate, (3) 6V4983 Driver Shaft, (4) 4M6013 Washer, (5) 5F9871 Nut. Assemble these parts as shown.

(1) Carefully clean all metal chips, and any other foreign material, from the counterbore area of the cylinder block, and also from the insert. Use 6V1541 Quick Cure Primer, as shown, to help in the cleaning process.

NOTE: Do not use retaining compound.

(2) Put a thin bead of 3S6252 Sealant all the way around outer edge (A) and inner edge (B), at the bottom of the insert counterbore.

NOTE: The insert must be installed as soon as possible after installation of the 3S6252 Sealant (5 minute maximum delay) before a film is present and starts to form on the sealant.

(3) Put an insert (6) in position on the cylinder block. [Each groove (C) of an insert must be in alignment with a specific head stud or bolt hole in the top surface of the cylinder block.] Install the insert installer assembly. The grooves in 6V164 Insert Installer (1) must be in alignment with grooves (C) in insert (6). Use 1P5546 Crossblock (7) and two 5D9514 Bolts (8) with 6N130 Washers to pull the insert into the cylinder block.

(4) Tighten bolts (8) alternately, one-half turn at a time. When the insert is installed all the way, and it is solid in the bore, hit driver plate (1), not too hard, with a hammer. Tighten the bolts to 100-150 lb.ft. (135-205). Keep this torque on the bolts for a minimum of one minute.

(5) Remove crossblock (7), then clean any extra sealant, as shown, that came out during the insert installation procedure.

Install only one insert at a time, then check the installation position. Acceptable limits for insert installation are: (a) the top surface of the insert must be even with the top surface of the cylinder block, or, (b) the top surface of the insert can be a maximum of .004" (0.10) below the top surface of the cylinder block.

NOTE: If the top of an insert is above the top surface of the cylinder block, that insert must be machined so it is even with the top surface of the cylinder block, before installation of the next insert.

(6) Use the 1P5510 Liner Projection Tool Group to see if the insert is even with the top of the cylinder block. If the top of the insert is above the top surface of the cylinder block, install the counterboring tool group and machine the top of the insert until it is even with the top surface of the cylinder block.

NOTE: The cutter must be sharp or it will chatter (have rapid vibration while cutting). It is better if the insert is machined with several quick operations of the tool group, for short periods of time.

(7) Use the 8S3140 Counterboring Tool Arrangement to cut the cylinder liner counterbore to the correct depth. See Special Instruction Form FM055228 for procedure.

(8) Install the cylinder liners. Check cylinder liner projection. See the Service Manual for cylinder liner projection specifications.

NOTE: For 5.75" (146.1) Bore, 4 cylinder engines, see Special Instruction Form SMHS7982 for installation of 5N8869 Water Seal Ferrules.

Cutters that are not sharp can be sent to: Porta-Tool, Inc., P.O. Box 307, Clovis, California 93612, to be resharpened (made sharp again).

A Cutter Sharpener Model No. PBS-203, shown above, is available from Porta-Tool, Inc.