PUMP GP-GEAR 3G9891 - Caterpillar

All Caterpiller Engines With Cylinder LinersThe 5P1618 Tool Arrangement or the 5P4175 Boring Tool Group (1), with the necessary tools given in the tool application chart on page 2, are used to cut away material from the cylinder liner counterbore, or the top face of the cylinder liner counterbore, or the top face of the cylinder block on engines that use a spacer plate, and install a new insert in the machined counterbore. The 5P1618 Tool Arrangement has all the tools needed for 6.25" (158.7) bore engines. Additional tools, that can be used with the 5P1618 Tool Arrangement, are available for other engines; see the tool chart on page 2. After installation of the inserts, use the 8S3140 Counterboring Tool Group to cut away material from the insert to get the correct liner projection (height).Tool Application Chart Always remove the spacer plate from the cylinder block, on those engines that have a spacer plate, before doing the counterboring procedure.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.2. Assemble tool holder (1) onto 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. (6.9 0.7) torque.3. With the boring tool in the horizontal position, remove plug (5) and check the oil level in the hydraulic feed unit. Fill the unit with SAE10W, 20W, or 30W oil. Install plug (5). Loosen knob (4) to release the feed control valve and move tool holder (1) in and out several times. Remove plug (5) and again check the oil level. Fill with oil if necessary and install plug (5). Tighten knob (4). If the oil level is low, the tool may not cut smoothly.4. Install the boring tool on the cylinder block. Release the feed control valve by turning knob (4) counterclockwise; the tool holder will then move down into the cylinder liner pilot bore.5. Make an adjustment to nut (6) until tool holder (1) is engaged in the pilot bore approximately .25" (6.4) as shown. Cylinder block (A) does not use a spacer plate; Cylinder block (B) does use a spacer plate.6. Tighten screw (7), to hold nut (6) in place. Install a minimum of three bolts (8) and washers. Tighten bolts (8) just enough to hold the boring tool in place, yet loose enough to let the boring tool be moved if necessary. While turning the tool holder manually with nut (6), tighten bolts (8) to 50 5 lb. ft. (6.9 0.7) torque. The tool holder should turn freely after bolts (8) are tightened. To