Installation Of 1W6265, 1W6266 And 1W6267 Insert For Cylinder Liner Seat{1217} Caterpillar

Inserts 1W6265, 1W6266 and 1W6267 that are similar to 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 5P936 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.

NOTE: Each of the three different inserts given here has a design for use in a specific location and in specific engine models. This information is as follows:

1W6265 - cylinders number 2, 3, 5 and 6 for all 6 cylinder, 6.25" (158.8) bore engines.1W6266 - cylinders number 1 and 4 for all 6 cylinder, 6.25" (158.8) bore engines.1W6267 - all cylinders for all V8, V12, V16 cylinder, 6.25" (158.8) bore engines.

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.

^*5P1630 Adapter^*5P1632 Holder Group^*5P1644 Cutter Gauge^*5P1645 Tool Group^*5P1656 Hook^*5P1769 Washer (4)^*5P4175 Boring Tool Group^*1D4614 Bolt (4)5P8603 Cutter Gauge5P8604 Cutter Gauge5P8605 Cutter Gauge5P8606 Cutter Assembly6V156 Depth Master Gauge6V157 Depth Master Gauge6V165 Insert Installer6V4986 Guide Plate6V4983 Driver Shaft5F9871 Nut4M6013 Washer1P5546 Crossblock1D4616 Bolt (2)5H1504 Washer (2)

Modification Of Boring Tool Base Adapter

NOTE: If the boring tool group has a Serial Number of 325-up, this modification procedure is not necessary because it will have been done by the tool manufacturer.

(1) Remove base adapter (1) from the drive assembly. Be sure to put a mark on the drive assembly and a mark on the base adapter, so the adapter can be installed in the same position.

(2) Remove material from the areas shown as location (A). Dimension (B) is approximately 0.7" (17.5).

(3) Turn base adapter (1) over and make the bore larger (bottom side) according to the dimensions shown.

(4) Install base adapter (1) on the drive assembly so it is in its original position.

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. (68 ± 6.8) 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 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 7.535" (191.4).

(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) for the feed control valve to lower the tool holder until cutter (1) is against the top 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 tool-holder 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 7.800" (198.1) and do steps 1 through 7. Then adjust the cutter to 8.000" (203.2) and do steps 1 through 7.

(11) Put the 5P8603 Master Gauge (12) 8.100" (205.74) 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. Caution: 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 8.100" (205.74).

(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 the 5P8604 Master Gauge (1) 8.200" (208.3) 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 (1).

(2) Put cutter (3) into micrometer fixture (2). Adjust cutter (3) to 8.200" (208.3).

(3) Install both pieces of 6V156 Depth Gauge (4) .354" (8.99).

NOTE: Depth gauge (4) must be kept in this location for the remainder of the counterbore work.

(4) Clean the tool holder slot carefully before installing the cutting tool. Install cutter (3) into the slot, and push the tool back into the slot as far as it will go. Tighten screw (5). Lower cutter (3) until it is .06" (1.5) above the top face of the cylinder block. Close the feed control valve.

(5) Use the heavy duty industrial drill and adapter (7) to operate the boring tool. Make the rough cut of 8.200" (208.3)

(6) Stop the cutter rotation immediately when adjusting nut (8) is against positive stop (9). Loosen knob (6).

(7) Lift the cutter out of the cylinder block and tighten knob (6) again. Loosen screw (5) and remove cutter (3) with 5P1656 Hook (10).

(8) Put 5P8605 Master Gauge (11) 8.300" (210.82) 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 (11).

(9) Remove the master gauge and put cutter (3) into micrometer fixture (2). Make an adjustment to cutter (3) until it is the exact same size as the master gauge.

Show/hide table

NOTICE
Be careful not to loosen screw (C) too fast, because the adjustment of cutter (3) has a spring load behind it and damage may be caused to the cutting edge.

(10) Clean the tool holder slot carefully before installing the cutting tool. Install cutter (3) into the slot, and push the tool back into the slot as far as it will go. Tighten screw (5). Lower cutter (3) until it is .06" (1.5) above the top face of the cylinder block. Close the feed control valve by turning knob (6). Start the finish cut of 8.300" (210.8).

(11) Make the complete finish cut without stopping. Stop the cutter rotation immediately when adjusting nut (8) is against positive stop (9). Use fine emery paper as shown, to remove any burrs from top face (B) of the cylinder block.

(12) 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 (12). The correct dimensions is .540" (13.72).

(13) Use emery paper to remove all sharp edges. Use a small file to remove any sharp edges that can break off around the stud holes and water holes. Use a 3/4"-10 thread tap to clean the threads of stud holes (D). Thoroughly clean the counterbores, stud holes and water holes for each cylinder.

(14) Measure as shown to find the thickness of the material that is between the edge of the 8.300" (210.82) diameter bore and the edge of the large water holes. Check this dimension for each of the large water holes that are near the 8.300" (210.82) diameter bore. The minimum permissible thickness is .080" (2.0) of material. For any of these locations that have a thickness less than the minimum permissible thickness, it will be necessary to install a 5N8869 Water Ferrule in that specific hole. See Special Instruction Form SMHS7982 for water ferrule installation procedure.

Installation Of 1W6265, 1W6266 And 1W6267 Inserts

Tools needed to install the inserts are: (1) 6V165 Insert Installer, (2) 6V4986 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 inserts. Use 6V1541 Quick Cure Primer 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. Put a drop of 3S6252 Sealant at each of four equally spaced locations in groove (C). [Groove (C) is in the bottom side of each insert (6).]

NOTE: The sealant put in groove (C) is to hold a seal in the bottom of the insert. After the sealant and seal are installed in the insert, install the insert in the counterbore as soon as possible (5 minute maximum delay), before a film is present on the sealant.

(3) Install a 6V5098 Seal (7) in groove (C) of each insert (6).

(4) Put the insert in position on the cylinder block. [Put grooves (D) of the insert in alignment with the bolt or stud holes in the cylinder block.] Install the insert installer assembly. Grooves in 6V165 Insert Installer (1) must be in alignment with bolt holes where necessary. Use 1P5546 Crossblock (8) and two 1D4616 Bolts (9) with 5H1504 Washers to pull the insert into the cylinder block.

(5) Tighten bolts (9) 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 five minutes.

(6) Remove crossblock (8), then clean any extra sealant, as shown, that came out during insert installation.

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 the insert is above the top surface of the cylinder block, the insert must be machined so it is even with the top surface of the cylinder block before the next insert can be installed.

(7) 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.

(8) Use the 8S3140 Counterboring Tool Arrangement with the 5P8626 Cutter to cut the cylinder liner counterbore to the correct depth. See Special Instruction Form FM055228 for procedure.

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

See Special Instruction Form SMHS7982 for installation of 5N8868 and 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.