Using The 6V-7770 Valve Guide Kit And 6V-7755 Spring Seat Guide{670, 1104} Caterpillar

Using The 6V-7770 Valve Guide Kit And 6V-7755 Spring Seat Guide{670, 1104}

Usage:

1100 (36B, 95B, 96B, 97B, );
3100 (96M, 97M, 98M, 65P, 66P, 67P, 68P);
3204 (2TB, 7EB, 3PC, 6DC, 45V);
3208 (29A, 30A, 9WC, 5CD, 5YF, 6SF, 2HG, 4NG, 90N, 99R, 40S, 75V, 62W, 32Y, 1Z, 2Z, 3Z, 51Z, 93ZEngines );
D3 (2PC, 6PF, 7JF, 5KG, 1PJ, 6N, 79U, 82U, 83U, 23Y, 24Y, 27Y, 28Y);
D4 (8PB, 9DB, 2AC, 3AC, 2XF, 8ZF, 1RJ);
D5C (6PJ, 3MK Track-TypeTractors );
EL180 (1RF, 4EF, 1BG);
215 (2XC, 4JC, 57Y, 14Z, 61Z);
225 (51U, 61X);
227 (10W Excavators);
508 (9NC, 2HD Wheel Skidders);
613 (71M, 38W Wheel TractorScrapers );
910 (29D, 80U, 40Y, 41Y);
916 (2XB, 9WB, 3SC, 8GC, 5GD, 5KG);
926 (1CB, 3TB, 4NB, 8NB, 4TC, 7TC, 1SD, 94Z Wheel Loaders);
931 (8N, 10N, 78U, 81U, 25Y, 26Y, 29Y, 30Y);
943 (3Y, 31Y, 4Z, 19Z);
953 (2RB, 1XK, 76Y, 77Y, 78Y, 5Z, 20Z, 44Z Track Loaders);
IT12 (4NC, 1FF);
IT18 (4ZD, 1DF, 2NJ);
IT28 (8JB, 2KC, 5SD, 1HF, 1JKIntegrated Tool Carriers)

Introduction

The 6V-7770 Valve Guide Kit and 6V-7755 Spring Seat Guide are used to install 6I-2864 (Intake) Valve Guides and 6I-2865 (Exhaust) Valve Guides when the valve guides have been worn beyond the maximum USE AGAIN tolerances.

The former 4W-3778 (Intake) Valve Guide and 4W-3779 (Exhaust) Valve Guides have been canceled and replaced by improved 6I-2864 (Intake) and 6I-2865 (Exhaust) Valve Guides.

The new valve guides feature a threaded design for improved lubrication and a material change for improved wear resistance.

This instruction lists the required/recommended tools, procedures and reference publications for the repair of the valve guides and installation of the valve guide sleeves.

NOTE: The 6V-7770 Valve Guide Kit and 6V-7755 Spring Seat Guide must be used with a 6V-3095 Boring Fixture and a 6V-3108 Boring Fixture Kit to machine the valve guides to accept installation of the valve guide sleeves.

Reference: SEBF8162 .. Guideline for Reusable Parts and Salvage Operations .. and

SEBF8055 .. Guideline for Reusable Parts and Salvage Operations:

* Recommended for the procedures to remove the cylinder head and prepare them for cleaning and failure inspection.

GMG02562 .. Using the 5P3536 Valve Guide Gage Group:

* Recommended for the tools and procedures to measure the finish bore of the sleeve.

Related Service Manual:

* Recommended for disassembly/assembly and the machining specifications for the correct angle between intake/exhaust valves and valve guides.

NOTE: This instruction starts with the inspection of a CLEAN cylinder head with ALL related components removed.

Tools Needed:

6V-7770 Valve Guide Kit and 6V-7755 Spring Seat Guide

6V-7755 Spring Seat Guide

The 6V-7755 Spring Seat Guide consists of the spring seat guide only and is used as an adapter with the 6V-7770 Valve Guide Kit.

Application:

Measuring the Casting Wall Thickness

NOTE: The cylinder head used in the photographs in this instruction, has been machined to expose the area(s) for viewing tool positioning and the machining operations.

View from combustion side of cylinder head. The casting wall thickness at location (A) must be measured to determine if the valve guide seat can be salvaged (machined).

1. Use an FT-1720 Gauge or a calipers to measure the casting wall thickness at location (A).

NOTE: The FT-1720 Gauge is the preferred tool but calipers can be used.

If The Casting Wall Thickness Dimension is LESS Than Specification

* If the casting wall thickness dimension is LESS than 3.75 mm (0.148 in) the valve guide seat CANNOT be salvaged and the cylinder head MUST be replaced (new or remanufactured).

If The Casting Wall Thickness is WITHIN Specification

* If the casting wall thickness dimension is 3.75 mm (0.148 in) or GREATER the valve guide seat can be machined to accept a new valve guide sleeve.

Installing the Valve Seat Adapter(s)

2. Install correct size valve seat adapter (1), part of 6V-3108 Accessory Kit, on drill bushing (2).

NOTE: The adapter should be installed at the approximate center of the drill bushing's threads.

3. Install drill bushing (2) and 6V-7755 Spring Seat Guide (3) in 6V-3095 Boring Fixture (4).

Cylinder head positioned with exhaust ports facing upward.

4. Position cylinder head with exhaust ports facing upward.

5. Position boring fixture (4) as shown, on the valve guide to be machined.

6. Adjust the boring fixture to move and seat the adapters fully against the valve and spring seats.

* Tighten the adjustment screw to maintain (secure) the adapters position.

Installing the Alignment Bushing

7. Install alignment bushing (5) in fixture (4).

8. Install knob (6) on bushing (2).

9. Use alignment pin (7) to position the drill bushing and alignment bushing in alignment with the valve guide.

NOTE: The alignment pin should enter into each bushing WITHOUT interference.

10. Turn knob (6) to secure the fixture with the alignment pin position.

11. Remove alignment pin (7), knob (6) and bushing (5).

NOTE: The alignment pin should exit each bushing WITHOUT interference.

* Repeat procedure(s) if excessive interference is felt.

Machining the Valve Guide

009

* An electric drill with a 13 mm (.5 in) diameter bit capacity and with a speed range of 500 - 600 revolutions per minute is required to drive the:

* 12.065 mm (0.4750 in) Piloted Core Drill

* 12.700 mm (0.5000 in) Piloted Reamer

* 5P5173 Reamer .. 9.474 mm (0.3730 in) Diameter

* 5P5174 Reamer .. 9.500 mm (0.3740 in) Diameter

Machining and Installation Operations

The machining consists of four operations:

1. The first machining operation uses a 12.065 mm (0.4750 in) piloted core drill to machine the guide to the correct inside diameter to install the new valve guide.

2. The second machining operation uses the increased diameter of the valve guide as a pilot for the 12.700 mm (0.5000 in) piloted reamer used to machine the guide to the correct inside dimension to install the new valve guides sleeves.

* The installation of the new intake/exhaust valve guide sleeve is after the first and second machining operations.

3. The third machining operation machines (reams) the valve guide sleeve to a semi finish diameter of:

9.474 mm (0.3730 in).

4. The fourth machining operation machines (reams) the valve guide sleeve to a finish diameter of:

9.512 mm ± 0.013 mm (0.3745 in ± 0.0005 in)

010

1. Install 12.0650 mm (0.475 in) piloted core drill (8) in drill bushing and alignment bushing as shown.

NOTE: Position the cutting portion of the drill away from the material (not contacting) and lubricate the drill with 5P-5178 Cutting Oil (or equivalent), before turning the drill ON.

2. Start the drill and use a medium drill speed and STEADY medium feed rate to machine the guide.

* STOP and remove drill

* Remove alignment fixture

* Clean the machined bore with the 5P-5176 Brush and/or flush any machining debris with cutting oil

010

3. Install guide portion of the 12.065 mm (0.4750 in) piloted core drill (9) into the drill bushing and alignment bushing as shown.

NOTE: Position the cutting portion of the drill away from the material (not contacting) and lubricate the drill with 5P-5178 Cutting Oil (or equivalent), before turning the drill ON.

4. Start the drill and use a medium drill speed and STEADY medium feed rate to machine the guide:

* STOP and remove drill

5. Inspect the guides machined surface for any tool chatter and/or openings into the water jacket.

NOTE: Any minor tool chatter can be corrected during the following machining (ream - finish ream) operation.

Do NOT install new valve guide sleeves if ANY of the valve guides show any evidence of openings into the water jacket.

If any evidence of openings are present the remaining machining operations (ream - finish ream) can NOT salvage the cylinder head. The cylinder Head MUST be replaced (new or remanufactured).

010

6. Coat the machined surface of the valve guide and the outside of the valve guide sleeve with CLEAN engine oil.

7. Use valve guide driver (10) or a press to install the valve guide sleeves.

010

NOTE: Position the cutting portion of the reamer away from the material (not contacting) and lubricate the ream and inside diameter of the valve guide sleeve with 5P-5178 Cutting Oil (or equivalent), before turning the drill ON.

8. Start the drill and use a medium drill speed and STEADY medium feed rate to machine (ream) the sleeve:

* STOP and remove reamer