NEHS0733: 159-9404 Counterbore Tool Group For C10 through C13 {0705} Caterpillar

Engine

C-10 All

C11 All

C12 and C-12 All

C13 and C-13 All

Introduction

Important Safety Information

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Think Safety

European Union Compliant, CE marked

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Pinch point

Safety Section

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

General Information

Introduction

The 159-9404 Counter Bore Tool Group is used to salvage engine block liner seats which are cracked or damaged. The liner seat is machined deeper and an insert shim is installed. The 159-9404 Counterbore Tool Group contains the items needed for machining "back cut liner seats" which are unique to C-10, C-11, C-12, and C-13 Engines. Refer to Table 2 for liner seat depth and insert shim usage.

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159-9404 Counter Bore Tool Group Refer To Table 1 For Item Identification

Cylinder Bore Nomenclature

Illustration 4	g02890520
(A) Liner Pilot Diameter (B) O-ring Sealing Surface Diameter (C) Liner Seat Ledge

Additional Contact Information

For additional product support questions concerning this tool, contact the Cat Dealer Service Tools hotline at:

Machining Setup and Procedure

This procedure can be performed either in or out-of-chassis. If the in-chassis procedure is used, cover the crankshaft journal oil holes to prevent debris from entering the engine block.

1. Prepare and measure the depth of the liner seat.

   1. Remove the cylinder head, piston, and liner.

   2. Make sure that the top deck of the cylinder head is clean and free of burrs.
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      Illustration 5	g02893416
      Set Dial Indicator To Zero

   3. Place the 9U-7993 Depth Gauge Assembly (indicator) and tip on the top deck and set the dial to zero.

      Note: The 3/8 inch "Bell Stylus", part of 9U-7993 Depth Gauge Group, is recommended for this procedure. Any tip can be used if adequate contact is made with the liner seat ledge. Make sure that the same tip being used for the procedure is used to zero the indicator.

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      Illustration 6	g02893417
      Install the 170-6555 (100 mm) Stylus Extension

   4. Install the 170-6555 (100 mm) Stylus Extension (6) and the same tip used to zero the indicator.
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      Illustration 7	g02893418
      Record Measurements At Four Places

   5. Measure and record the liner seat ledge depth in four places, 90 degrees apart. Add the indicator depth measurement to 100 mm for the actual cylinder bore depth. Refer to the Service Manual, SENR6593 for specifications and procedures.

      Note: Make sure that the indicator tip is set on the flat surface of the liner seat ledge. See Figure 8 for an example.

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      Illustration 8	g02893439
      Make Sure That Indicator Tip Is On Flat Surface Of Liner Seat Ledge

   6. Subtract the smallest measurement from Step 1.e from the largest measurement. This measurement is the minimum amount of material that must be removed to clean up the liner seat. Use Table 2 to determine the exact amount that based on the shims thickness.
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   Illustration 9	g02893440
   Install Tool Bit (4) Cutter Plate (5) Cutter Bit (13) Cutter Bit Adjuster (14) Cutter Bit Locking Screw

2. Install cutter bit (5), if not already installed.

   1. Loosen the cutter bit locking screw (14).

   2. Install cutter bit (5) into cutter plate (4) by turning cutter bit adjuster (13) clockwise with 159-9398 Hex Key (11).

      Note: The face of the cutter bit must be facing towards the clockwise rotation of the cutting operation.

   3. Make sure that the tip of the cutter bit does not extend beyond the outer diameter of the cutter plate.
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      NOTICE
      If the cutter bit extends beyond the cutter plate diameter, bit will be broken off and/or can damage the O-ring sealing surface when installing the counterbore tool into the cylinder block. Damage to the O-ring sealing surface can also allow coolant to leak into the engine block.

   4. Do not tighten cutter bit locking screw (14) at this time.

3. Install cutter plate (4), if not already installed.

   1. Install the cutter plate onto the main shaft of the counterbore tool.

   2. Insert the 159-9400 Cutter Plate Wrench (10) into the hole in the side of the cutter plate and tighten securely.

4. Position the cutter plate in the cylinder bore.

   1. Position the cutter plate in the cylinder bore by raising both depth set collars and lowering the cutter plate into the counterbore. The cutter plate will center in the O-ring sealing surface diameter. Before centering, make sure that the cutter plate is not touching the liner seat ledge.

      Note: Using the 1U-8265 Penetrating Oil or equivalent will help the cutter plate freely rotate in the bore.

   2. Rotate the handle of the counterbore tool and allow to center.
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      Illustration 10	g02893736
      Position The Counterbore Tool And Secure With Bolts And Square Washers

   3. Secure the base of the counterbore tool to the cylinder block with four 8T-0358 Bolts (8) and 159-9395 Square Washers (9). Cross tighten the bolts to 41 N·m (30.2 lb ft) while rotating the cutter plate. After tightening the bolts, make sure that the cutter plate rotates freely.

   4. Lower both depth collars until the lower collar contacts the body of the counterbore tool.

5. Adjust the cutter bit. Use a flashlight to see the cutter bit.
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   Illustration 11	g02893459
   Install Spacer Block

   1. Using the T-handle, raise the cutter plate up off the liner seat approximately 12 mm (0.5 inch) and install spacer block (3). This will ensure the cutter bit is not touching the liner seat ledge.

   2. Using 159-9398 Hex Key (11), turn the cutter bit adjusting screw counterclockwise until the cutter bit just touches the O-ring sealing surface.

   3. Remove spacer block (3).
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      Illustration 12	g02893463
      Turn Bottom Depth Set Collar To Lower Cutter Plate

   4. Turn the bottom depth set collar and slowly lower the cutter plate until the cutter bit just touches the liner seat ledge.

   5. Rotate the bottom collar five graduations in a clockwise direction to raise the cutter bit. Each graduation on the collar is one thousandth (.001) of an inch. Use the scribed line on the chamfered portion of the counterbore tool to count the graduations.
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      Illustration 13	g02893476
      Adjust The Cutter Bit

   6. Turn the cutter bit adjustment screw counterclockwise until the tip of cutter bit contacts the deepest diameter of the counterbore. If the cutter bit will not adjust, turn the bottom depth set collar clockwise five or more graduations and readjust.
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      Illustration 14	g02893478
      Correctly Set Cutter Bit Tool

   7. Tighten the cutter bit locking screw.

6. Zero the depth set collars.

   1. While turning the T-handle, rotate the bottom depth set collar counterclockwise and slowly lower the cutter plate into the bore until the cutter bit touches the liner seat ledge. Lock the bottom depth set collar in place.

   2. Rotate the top depth set collar down against bottom depth set collar.

7. Set the depth of the cut.

   1. Rotate the top depth set collar counterclockwise, using the graduations, by the amount determined in Step 1.f. Each graduation on the depth collar increases the depth of the cut by 0.03 mm (0.001 inch).

   2. Tighten the thumbscrew on the top depth set collar.

8. Cut the counter bore.

   1. Fill the oil cup on the counterbore tools main housing with 30W oil to maintain lubrication during this machining procedure. A lightweight or penetrating oil can also be used to keep the cutter plate rotating freely.

   2. Rotate the bottom depth set collar counterclockwise a maximum of two graduations 0.05 mm (0.002 inch) or less and tightened the thumbscrew securely. Machining too much material at one time can cause chattering.

   3. Cut the counterbore by turning the T-handle clockwise while maintaining a constant downward pressure on the handle.

      Note: Do not stop turning the handle at the same position after each cut. Alternate the stopping position to avoid creating a ridge in the counterbore. Also, if chatter occurs, take smaller cuts until the chatter is removed.

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      Illustration 15	g02893502
      Machine The Liner Seat

   4. Continue to raise the bottom depth set collar until the top depth set collar is touched.

      Note: To ensure a smooth machined finish, make the final cut 0.03 mm (0.001 inch).

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   NOTICE
   Never rotate the cutter plate in the counterclockwise direction or the cutter bit will be damaged.

9. Retract the cutter bit.

   1. Loosen the cutter bit locking screw.

   2. Turn the cutter bit adjusting screw clockwise until the cutter bit is fully retracted into the cutter plate.

   3. Remove the four mounting bolts and remove the counterbore tool.
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   Illustration 16	g02893516
   Measure The Depth Of The Newly Machined Bore

10. Verify the depth of the bore. The number of shims will be determined by using Table 2.

11. Select the appropriate liner shims.

    1. Use Table 2 to select shims that make the counterbore depth equal to original 100 mm ± .03 mm (3.94 in ± 0.001 in) depth. Shims can be stacked as needed.
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       Illustration 17	g02893536
       Install Shims

    2. Install the proper shims into the counterbore. Shims may need a slight twist to help fit into the counterbore.

    3. Remeasure the depth of the counterbore and verify that depth is within the 100 mm ± .03 mm (3.94 in ± 0.001 in) specification. If not, remachine the depth or add additional shims.

    4. Make sure that all the shims are properly centered before installing the liner. The bumps on the outside of the shims are designed to help center the shim in the bore.
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       Illustration 18	g02893539
       Install Cylinder Liners

    5. Install the cylinder liner without the O-ring and check liner projection with the 8T-0455 Liner Projection Indicator Group. See Special Instruction, SENR6593 for additional information.