CARTRIDGE GP-TURBOCHARGER 2555477 - Caterpillar

1100 Series And 3208 Truck EnginesThe method formerly used to remove the cylinder sleeve from the cylinder block was to machine the sleeve until it was thin enough to be removed.
A new procedure and a new tool can be used to remove the cylinder sleeve from the cylinder block. This new procedure is faster than the former method. The new procedure is as follows:
1. Make a bend in a 3.18 mm (.125") diameter electrode as shown in Illustration 1. The electrode used must meet AWS E6013 standards.2. Use an arc welder that is set at 100 amperes and 18 volts to put two beads of weld in the sleeve. The welds should be approximately 51 mm (2 ") apart.
Illustration 1. Angle of electrode and location of two welds.
Do not get closer than 6.4 mm (.25") to either end of the sleeve. If the weld extends to the end of the sleeve, the sleeve will be tack welded to the cylinder block. Also, move the electrode at a minimum rate of 406 mm (16 ") per minute so that the electrode does not burn through the sleeve and cause damage to the cylinder block.
These two welds will cause a separation between the sleeve and the cylinder block in the area between the two welds.
3. A standard tire iron can be used to make an FT1850 Chisel as shown in Illustration 2. The length of the new chisel should be at least 356 mm (14 "). A drawing of the FT1850 Chisel is available from your Division Service Manager.
Illustration 2. FT1850 Chisel.4. Use the FT1850 Chisel to remove the section of the sleeve that is between the two welds. See Illustration 3.
A shoulder in the bottom of the cylinder block holds the sleeve in position. Use caution when the FT 1850 Chisel is used so that this shoulder is not damaged.
5. After removal of the section between the welds, the remainder of the sleeve can be removed.
Illustration 3. Removal of section from cylinder sleeve.