GEAR 8E7864 - Caterpillar

introduction
* Dimensions in inches (mm)
Indicates change.The 9N6275 Cylinder Sleeve can be used for reconditioning of the cylinder blocks for the engines above, when oversize pistons cannot be used, or because of pin holes, cracks or scoring in the cylinder walls. Make a good inspection of the cylinder block to be sure it is usable. Install the sleeves according to the procedure given in this instruction.Use the boring tools and the honing machine given in the chart that follows, or equipment with equal precision, to give the machined specifications given in this instruction. Additional tools needed are also given in the chart. Boring specifications for cylinder sleeve installation
Dimension (A) is the original bore diameter.1. Put the boring tool in position. Use the centerline of the original cylinder bore, and make the new bore to a size of 4.6865"Ø .0005" (1190.38Ø 0.013), dimension (B), to a depth of 7.747" .005" (196.77 0.13), dimension (C). Dimension (C) is measured from the top surface of the cylinder block. The new bore size must be within .002" (0.05) total runout of the centerline of the original cylinder bore.2. The angle at location (D) is 0.01" X 45° (0.3x45°) maximum. 3. Remove the sharp corner, or any burrs at the bottom edge (E) of the bore. A slight chamfer at location (E) is permissible.installation of cylinder sleeve
1. Remove the 9S6074 Adjusting Screw and 1P2329. Insert from 1P820 Hydraulic Puller (1) and install 6V2183 Forcing Screw (2). Put clean No. 2 disel fuel on sleeve (3). Use hydraulic puller (1) with forcing screw (2) and 1P2393 Puller Plate (4), 6V2195 Speed Nut (5), 6V2194 Puller Plate (6) and 1D5119 Nut (7) to pull sleeve (3) into the cylinder bore, until the bottom of the sleeve comes in contact with the counterbore [locations (A)] at the bottom of the bore. 2. After installation of sleeve (3) in the new bore, it is permissible for a maximum of .005" (0.13), dimenstion (B), of the sleeve to be above the top surface of the cylinder block. It is also permissible to machine the top end of the sleeve, if desired, so it is even with the top surface of the cylinder block.3. At the inside diameter [location (C)], at the top of the insert, machine a 30° chamfer .040" .010" (1.02 0.25) deep. For engines that have a 5.00" (127.0) stroke, grind away any part of the sleeve that extends below edge (D), into the connecting rod clearance area shown. 4. If not already done, use the 1P3565 Chamfering Group as shown, to remove the sharp corner at the bottom of each cylinder bore. This is necessary to prevent any scuffing of piston skirts. The chamfer must be approximately 10° x .09" (10° x 2.3).5. Hone the bore of each cylinder sleeve according to the specifications in the chart that follows. Mount cylinder block on .675" (17.145) riser plates. Use 42" (1067) long bar, move clamps and riser blocks to extreme