Usage:
The former Cylinder Block Service Assembly for the engine in the machines in the list above has been cancelled. This former cylinder block had a counterbore for the seat of the cylinder liner, and also used studs and nuts to fasten the cylinder heads to the cylinder block. The new Cylinder Block Service Group is a spacer plate design, and bolts and washers are used to fasten the cylinder heads and spacer plates to the cylinder block. Several new parts are needed to make a replacement of the former service block assembly with the new service block group. See the chart that follows for the parts needed according to the engine and machine for which the reconditioning is being done.
1. Install additional parts, from the 7N4134 Hardware Kit, on the 7N1497 Cylinder Block Assembly according to the chart. Put a 3S5496 Seal on each hollow dowel (7) before installation of the spacer plate gasket. If the starting engine and the diesel engine have a common lubrication system, remove plug (8). If the machine is equipped with a hydraulic decelerator, remove plug (9). Remove plug (10) to give lubrication to the three-stage torque converter on D9 (34A, 50A).
2. Install the cylinder liners with new O-rings and a new top band.
NOTE: The former cylinder liners can be used in the new cylinder block if, after careful inspection, they are found to be acceptable. If the new 7N5037 Piston Groups are to be installed in the former cylinder liners, the cylinder liners must be honed according to the procedure in Special Instruction Form SEHS7220, USE OF THE 5P8595 HONING TOOL GROUP.
Timing Gear Housing Rework Procedure
Two bolt holes at the top of the former timing gear housing, are too high for use with the new service cylinder block assembly. The housing can be reworked, according to the instructions that follow, and can then be installed on the new cylinder block assembly. Always use the new 7N3034 Gasket with a reworked timing gear housing, or when a new timing gear housing is installed.
NOTE: If the former timing gear housing is reworked and installed on the new service cylinder block, some of the bolt holes in the timing gear housing will not be used. This will not cause a problem, because the gasket for the timing gear housing will seal the bolt holes.
1. Use the dimensions shown above and make a mark at locations (A) and (B).
NOTE: Use the center of dowel hole (C) as the point from which to start to make the measurements for the dimensions shown above. Drill a 1.500" Ø (38.10 Ø) hole at locations (A) and (B).
(2) Use a 1 1/4" NPT tap and make threads in the two holes. The threads must be deep enough so 1 1/4" NPT solid cast iron pipe plug can be installed and be flush (even) with the inside face of the timing gear housing.
NOTE: On most housings, a small amount of cast opening can still be seen, such as at locations (D) and (E). This is acceptable.
(3) Use 8M8060 Quick Cure Primer to clean the threads in the holes, and the threads on the pipe plugs. Put 5P3413 Pipe Sealant on the threads and install the pipe plugs. Machine (grind) the ends of the pipe plugs so they are flush with the surface of the timing gear housing that is toward the cylinder block.
(4) Use the dimensions shown above and drill a .547" Ø (13.89 Ø) hole at locations (F) and (G). Put a 1.125" Ø (28.58 Ø) spotface around the two holes, on the timing gear side of the housing.
(5) Drill two holes (H), and make threads in the holes for 10-32 screws. Drill the holes from the opposite side from where holes (A) and (B) were drilled. Do not drill holes (H) deeper than .31" (7.9). Install a 10-32 screw in each hole and machine the ends so they are even with the surface of the timing gear housing that is toward the cylinder block.
Engine Assembly
1. For installation of the spacer plates and cylinder liners, and for the check of cylinder liner projection, for both diesel and gas engines, see Service Manual Forms SENR7044-01 and SENR7045-01.
2. For installation of all other parts, from the former cylinder block to the new cylinder block, such as crankshaft, connecting rods and pistons, flywheel, etc., except for cylinder head installation,see the Service Manual for the former engine.
3. Remove the valves, valve springs, etc., from the former cylinder heads and install them in the new cylinder heads. See the Service Manual for procedure.
NOTE: For vehicular engine applications it is necessary to install new oil return lines from the turbocharger to the cylinder block. The oil return port in the cylinder block is in a different location on the new cylinder block.
Cylinder Head Installation And Bolt Tightening Procedure
1. Install the new head gaskets, water seals and cylinder heads. Put 9M3710 Anti-Seize Compound on the threads of the head bolts. Install and tighten the head bolts according to the sequence and torque that follows.
a) Tighten bolts 1 thru 20 to ... 180 ± 10 lb.ft.(247 ± 14 N·m)
b) Again tighten bolts 1 thru 20 to ... 300 ± 10 lb.ft.(410 ± 14 N·m)
c) Tighten bolts 21 thru 25 to ... 75 ± 10 lb.ft.(100 ± 14 N·m)
d) Again tighten bolts 1 thru 20 (hand torque only) to ... 300 ± 10 lb.ft.(410 ± 14 N·m)
e) Again tighten bolts 21 thru 25 to ... 75 ± 10 lb.ft.(100 ± 14 N·m)
NOTE: Use 8F4225 Bolts with 5H1504 Washers to fasten 7N5582 Lifting Eye (rear) to the cylinder head. Use a 7N5590 Plate, two 684117 Bolts and two 6N3376 Washers to install the front, 7N5591 Lifting Eye. Put the plate between the cylinder head and the bottom of the lifting eye on Industrial Engines only.
(2) Install the valve cover base, rocker arms, etc., according to the instructions in the Service Manual.