TM-5-3805-254-14-P-2
TRUCK, DUMP, 20 TON, 6X4, ON-OFF HIGHWAY 71,000 GVW, IHC MODEL F-5070 (CCE)
TECHNICAL MANUAL; OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT, GENERAL SUPPORT AND DEPT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE INSTRUCTIONS)
JUNE 1980
TM-5-3805-254-14-P-2 - Page 362 of 894
TRUCK SERVICE MANUAL
3. Use ST-663 Valve Guide Arbor and ST-257
Valve Seat Insert Tool Driver, Fig.
2-10, to hold and
drive ST-662 Valve Seat Insert Cutter when cutting valve
seat insert counterbore.
4. Cut counterbore 0.006 to 0.010 inch [0.15 to
0.25 mm] deeper than insert thickness to permit staking
or peening of head to hold insert.
Allow cutter to dwell
upon reaching proper depth to insure a flat seating
surface.
5. Install valve seat insert and stake insert in head
using ST-1122 Tool Driver over shaft of ST-1124 Insert
Staking Tool.
A 1/4 inch [6.35 mm] diameter round end
punch may be used if staking tool is not available.
CAUTION
Over-swaging around insert may crack cylinder head.
Grind Valve Seats
1. Use ST-685 Valve Seat Grinder and correct
arbor from ST-663 Valve Guide Arbor Set.
2. Check valve seat width, it should be 0.063 to
0.125 inch [1.59 to 3.18 mm], see (1 or 2, Fig.
2-4).
3. If seating area (1) is wider than 0.125 inch [ 3.18
mm] maximum, stock can be removed from points (3)
and (4) with specially dressed stones.
Narrowing should
not extend beyond chamfer on valve seat insert.
Chamfer provides metal for staking or peening.
4. Check valve seat concentricity with valve seat
indicator.
Total run-out should not exceed value listed in Table 2-1
(4).
Replace Injector Sleeves
Remove injector sleeves marked for replacement with
ST-1244 Injector Sleeve Puller and ST-1247 Impact
Socket Wrench or equivalent.
See Service Tool
Instructions.
Bead Or Cut Sleeve Seat In Head
Cylinder heads machined for 0.060 to 0.070 inch [1.52 to
1.78 mm] injector tip protrusion (after Engine Serial No.
781887) are machined 0.015 inch [0.38 mm] deeper than
previous heads.
Due to this change it may be necessary
to cut 60 deg.
beaded seat deeper to obtain 0.060 to
0.070 inch [1.52 to 1.78 mm] injector tip protrusion.
Cut
the 60 deg.
beaded seat with ST-788 Cutter.
It is
recommended that several light cuts be taken and the
depth rechecked until the correct depth is obtained.
Clean sleeve bore thoroughly with compressed air.
Sleeve Installation
1. Coat new "0" rings with clean engine lubricating
oil.
Install "O" ring into groove of head injector sleeve
bore.
2. Using ST-1227 or equivalent Injector Sleeve
Installation Mandrel, push new injector sleeve into bore
of cylinder head until it bottoms.
Do not strike mandrel
with hammer during this step.
Remove mandrel.
3. Install ST-1179 Injector Sleeve Holding Tool.
Tighten nut to 35 to 40 ft-lbs [4.8 to 5.5 kg m] torque.
4. Insert mandrel into sleeve bore, strike mandrel
two moderate blows with hammer to insure that Injector
sleeve is properly seated.
Retighten injector sleeve
holding tool to 35 to 40 ft-lbs [4.8 to 5.5 kg m] torque.
5. Roll top 1/2 Inch [12.70 mm] area of sleeve with
ST-880 Expanding Roller.
Fig.
2-11.
Use inch-lb [kg m]
torque wrench to turn ST-880; turn mandrel until a 75
inch-lb [0.9 kg m] maximum torque reading is obtained
on torque wrench.
CAUTION
Over-rolling of injector sleeve will cause deformation of
sleeve into "O" ring groove.
6. Cut injector seat to provide proper seat and
injector tip protrusion.
To determine amount of cut,
insert injector and torque to specifications, then measure
tip protrusion.
Depth of cut must provide 0.060 to 0.070
inch [1, 52 to 1.78 mm] protrusion of injector cup tip
beyond milled face of cylinder head when injector is
installed at proper torque.
7. Sleeve must "blue in" with Prussian Blue 360
deg.
around injector seat when injector is Installed in
cylinder head.
Bluing band
must
be
0.060
inch
[1.52
mm] minimum width.
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