Usage:
(158.8) Bore 6 Cylinder Diesel Engines
The 5P8595 Honing Tool Group is needed to remove the wear ridge that is toward the top of the cylinder liners of the engines above. If the cylinder liners have been used with either the 6N6642 Piston Groups or the 3S5502 Piston Assemblies, the wear ridge must be removed before the new 7N5037 Piston Groups can be installed.
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The top ring on these new pistons is 1.02 (.040") higher on the piston body than the top ring on the former piston body. It is necessary to remove the wear ridge before the new pistons are installed, or the result will be immediate damage to the top ring or the piston body at the time of engine start-up. |
Parts in the 5P8595 Tool Group are as follows: 1 - 5P8591 Stone Holder (two), 2 - 5P8590 Hone, 3 - 5P8594 Quick Coupler, 4 - 5P8592 Stone (two), 5 - 5P8593 Stone (two).
NOTE: Additional tools and material needed: 8 Liters (2.0 gallons) of honing oil [available in 5P8615 Honing Oil, 19 liter (5.0 gallon) cans or 1P7453 Honing Oil, 8 liter (2.0 gallon) cans]; 3/4" low speed electric drill; speed control for electric drill; 6.4 (.250") inside diameter, flexible plastic hose 3.6 to 4.6 m (12-15 feet); 1P3537 Dial Bore Gauge Group; FT1371 Holding Fixture (drawing for fabrication is available from Division Service Managers).
Measure the inside diameter of each cylinder liner. The largest dimension will normally be found near the upper (top) end of piston ring travel in the cylinder liner. Do not use the cylinder liner if the largest diameter is more than 158.9 (6.256").
(1) Use bolts to fasten FT1371 Holding Fixture (6) to a work bench and put in a position so there is good access to the drain plug. Keep the O-Ring seals on the cylinder liner and put plastic tubing (7) around cylinder liner (8), 4 to 6 times in a clockwise direction as shown and put the cylinder liner in the holding fixture. Fasten one end of tubing (7) on the holding pin at location (A) as shown. The other end is loose. Put 8.0 liters (2 gallons) of honing oil in the holding fixture, so there is approximately 3.0 (.12") of honing oil in the cylinder liner (8).
(2) Stretch (pull tight) plastic tubing (7) all around cylinder liner (8). Use the four bolts as shown and install plates (9) and (10) on cylinder liner (8).
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Plates (9) and (10) are used for safety purposes only. Do not tighten the bolts completely. The plates must be loose enough to give a small amount of cylinder liner movement during the honing procedure. This will help to prevent out-of-roundness in the bore of the cylinder liner. |
(3) Bend hone (2) approximately 90° at location (B) and remove pinion (11). Install stone holders (1) as far down as possible with the rack teeth toward the pinion hole, then install pinion (11).
(4) Install 5P8592 Stones (4) on stone holders (1) as far as they will go, and tighten screws (12). For coarse adjustment of the stone pull out on knurled nut (13) approximately 2.5 (.1") and turn the nut clockwise. For fine adjustment of the stone, engage lever (14) and turn it counterclockwise.
(5) Install hone (2) into the cylinder liner and adjust it to fit the inside diameter of the liner. Use quick coupler (3) and connect hone (2) to the electric drill. Put cover (15) in position on holding fixture (6). Put the chuck of the electric drill in the center of slot (C) and mark this location on the reaction bar (16). Drill a hole with a No. 8 drill and make 1/4"-20 threads at the location of the mark on reaction bar (16). Install eyebolt (17) (from the FT1371 Holding Fixture) in the tapped hole.
(6) Adjust stops (18) so the honing stones can go out of each end of the cylinder liner approximately 10.2 (.4"). Connect the speed control to the drill and adjust it to get a reduction of 20-30% of drill speed. Make reference to HONING PROCEDURE RECOMMENDATIONS on page 8.
NOTE: Approximately every 30 seconds, or when it is felt that there is a reduction in cutting friction, adjust lever (14) to get an increase in cutting pressure.
(7) Use the 1P3537 Dial Bore Gauge Group several times as shown, during the honing procedure, to make sure the cylinder liner is within specifications. When the wear ridge has been removed, install the 5P8593 Stones on the stone holders. Put the stones in the liner and adjust to a good honing pressure. Hone with the 5P8593 Stones for 30 seconds only. This stone is used only to form a plateau (remove any high spots) in the bore, and will change bore size very little.
(8) After each liner is finished with the honing procedure, wash and brush the liner with a strong detergent, dry and then lubricate the bore with lubrication oil.
The hone pattern must be visually the same in both directions, and must be free of large scratches when seen with a light.
Honing Procedure Recommendations
The honing pattern (design) is controlled by the rpm of the drill, rate of stroke and length of time used to change direction of the stroke while using the tools. Each operator must follow his own method of doing the honing procedure, to get the correct hone pattern in the bore of the cylinder liner. If it is necessary, change the rate of stroke, drill rpm and/or the length of time used to change direction of the stroke, to get the correct hone pattern.
NOTE: Do not decrease drill rpm too much, or the result will be an overload on the drill.
Stones that cut correctly will cut approximately 0.01 (.0005") per minute. At times, new stones will not cut until the glaze (smooth, shiny surface) is broken. This can be corrected by first rubbing the stone surfaces together (application of friction between stone surfaces). If the stones still do not cut, use a hacksaw to cut 2 or 3 grooves (A), on each side, 1.02 (.04") deep, at a 45° angle as shown.
NOTE: It is not necessary to run the honing oil through a filter, but it is necessary to change the oil at specific intervals.