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    Cylinder Liner Seat Milling

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    Oscar Alanis

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    © All Rights Reserved
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    Cylinder Liner Seat Milling

    Uploaded by

    Oscar Alanis
    9 views5 pages

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    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    Copyright:

    © All Rights Reserved
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    9 views5 pages

    Cylinder Liner Seat Milling

    Uploaded by

    Oscar Alanis

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 5

    Service Bulletin

    Volvo Trucks North America, Inc.


    Greensboro, NC USA Trucks
    This Service Bulletin replaces SB 213–40, “Cylinder Date Group No. Page
    Liner Seat Cutting (Milling), D12D” (11.02), publication 3.2003 213 40 1(5)
    no. PV776–TSP180846.
    Cylinder Liner Seat
    Milling
    D12D
    Cylinder Liner Seat Milling

    T2019762

    This information covers the proper procedure for milling (cutting) the cylinder liner seat
    on the VOLVO D12D engine.

    Contents
    • “Special Tools” page 2
    • “Cylinder Liner Seat, Milling (First)” page 3

    NOTE: Information is subject to change without notice.

    Illustrations are used for reference only, and may differ slightly from the actual
    engine version. However, key components addressed in this information are repre-
    sented as accurately as possible.

    PV776-TSP188335 USA13376
    Volvo Trucks North America, Inc. Date Group No. Page
    Service Bulletin 3.2003 213 40 2(5)

    Tools
    Special Tools
    For special tools ordering instructions, refer to Tool Information, group 08.

    9989876 9992479 9996966


    Dial Gauge Holder Press Tool

    9998272 PT6400C PT6410-4A


    Milling Cutter Cylinder Liner Puller Feet

    PT2900
    Chip Vacuum
    Volvo Trucks North America, Inc. Date Group No. Page
    Service Bulletin 3.2003 213 40 3(5)

    Service Procedures
    2139-05-03-01 3
    Cylinder Liner Seat, Milling
    (First)
    Liner removed, including shimming

    See also:

    • “Cylinder Liner Seat Milling” page 1

    You must read and understand the precautions and


    guidelines in Service Information, group 20, "General
    Safety Practices, Engine" before performing this pro-
    cedure. If you are not properly trained and certified in
    this procedure, ask your supervisor for training before
    you perform it.

    Special tools: 9989876, 9992479, 9996966,


    9998272, PT6400C, PT6410-4A
    Preparing to mill the cylinder liner seat
    1
    Remove the cylinder liner and clean
    the liner seat in the engine block; refer
    to Service Information, group 21. T2019670
    Mount dial gauge 9989876 in holder 9989876
    9992479. Position the holder with dial 9992479
    2 gauge across the cylinder liner.
    Place the cylinder liner in the cylinder 9996966
    without sealing rings. Secure it with 2
    cylinder liner press tools 9996966. 4
    Zero the dial gauge to the cylinder
    NOTE: Mark the liner position in the block with very slight (1 – 2 mm) pre-
    cylinder block so that it will be put back tensioning against the engine block
    in the same position during assembly. surface.
    Volvo Trucks North America, Inc. Date Group No. Page
    Service Bulletin 3.2003 213 40 4(5)

    5 8
    Calculate how much the liner seat
    must be machined to attain the correct
    liner height above the engine block
    surface.

    NOTE: Liner height (including shims)


    above block surface must be 0.15 –
    0.21 mm (0.006 – 0.008 in.). Try to
    achieve the upper tolerance.

    NOTE: Shims for adjusting cylinder


    liner height are available in 0.20 mm,
    0.30 mm, and 0.50 mm thicknesses.

    9
    Machine the liner seat as little as pos-
    sible so that the fewest shims are
    required.

    Example: mm
    T2019761

    Measure the height between the cylin- Specification: liner 0.21


    der liner and the engine block surface. height above engine
    Measure the liner height at two differ- block surface
    ent places diagonally against one
    Recorded value — 0.12
    another. Calculate the average of both
    the measurements. Difference 0.09

    NOTE: Always measure at the highest


    point on the sealing surface. Shim 0.20

    Difference — 0.09
    6 Maching required 0.11
    Remove the press tools.

    7
    Installing cutting (milling) tool
    10

    W2003962

    Using cylinder liner puller PT6400C PT6400C T2019727

    (and puller feet PT6410-4A), pull the PT6410-4A Place lower guide (D) of cutting tool
    cylinder liner from the engine block. 9998272 into cylinder.
    Volvo Trucks North America, Inc. Date Group No. Page
    Service Bulletin 3.2003 213 40 5(5)

    11 17
    Install milling cutter and shaft (C) so Continue turning the milling cutter until
    that shaft aligns with guide. it no longer cuts. Read the dial gauge
    to determine the depth of cut.

    12
    Install axial bearing and yoke (B); bolt 18
    yoke to cylinder block. Torque-tighten If not yet at the proper depth, turn the
    to 45 Nm (33 ft-lb). cutting height adjustment sleeve an-
    other 1/10 turn and rotate the milling
    NOTE: Loosen cutting height adjust- cutter.
    ment sleeve (A) before tightening yoke
    so there is no pressure on the cutter.
    19
    Repeat this process until the required
    13 machining depth has been reached.
    With the milling tool bolted down, turn
    the cutting height adjustment sleeve
    bolt so it presses very lightly against 20
    the milling tool. Remove the milling cutter and clean
    the liner seat using a chip vacuum or
    suction bag tool to remove metal fil-
    14 ings.
    Install and zero the dial gauge
    9989876.
    Final installation
    15 21
    Without putting any tension on the Install the same cylinder liner without
    tool, turn the milling cutter clockwise sealing rings, but with required shims,
    2–3 rotations to clean the liner seat. and recheck the measurement of liner
    height above the engine block surface.
    CAUTION
    22
    Never turn the milling cutter counterclockwise. Doing If the cylinder liner height is within tol-
    so can damage the cylinder liner seat. erance, install the cylinder liner with
    sealing rings; see Service Information,
    group 21: “Piston and Liner, Replace-
    ment (One).”
    16
    Turn the cutting height adjustment
    sleeve very slightly (approximately
    1/10 turn) so that the milling cutter is
    pressed against the surface. Rotate
    the milling cutter with an even move-
    ment.

    NOTE: Hold the adjustment sleeve to


    prevent it from turning while rotating
    the milling cutter.

    NOTE: Use a long ratchet for proper


    leverage and to make complete rota-
    tions.

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