[211 Db] Cylinder Block; Cylinder Sleeve Counterbore - Mack E7 Service Manual

5-101.bk Page 2 Friday, March 17, 2006 11:05 AM

[211 DB] CYLINDER BLOCK

Cylinder Sleeve Counterbore

SPECIAL TOOLS REQUIRED:
Counterbore Tool PT2210
Counterbore Cutter Plate PT2210-3A
Universal Dial Depth Gauge PT5025
Stylus Extension (3-Inch) PT5052-11
Hex Key Wrench PT2210-14
INSPECTION AND REPAIR
If the cylinder block deck is resurfaced, the
cylinder sleeve counterbore depth must be recut
to specification. If the cylinder block deck was not
resurfaced but cylinder sleeve counterbore
surface shows excessive pitting or erosion, recut
the counterbore as required.
Use shims to re-establish the correct liner flange
height. Shims are available in the following
thicknesses: 0.002, 0.003, 0.004, 0.008, 0.010,
0.012 and 0.014 inch.
To resurface the cylinder sleeve counterbore
area of the cylinder block, use counterbore
tool PT2210 with counterbore cutter plate
PT2210-3A.
This procedure can be performed either in or out
of the chassis. If performing the procedure in the
chassis, be sure to cover the crankshaft and any
holes in the block to prevent contamination from
machining chips.
Do not cut seats deeper than 4.034 inches
(102.464 mm).
1. Make sure that the top of the deck is clean
and free of burrs. Use a finish mill file and
crocus cloth, if necessary, to create a
smooth, flat surface for positioning the tool.
2. Using compressed air, thoroughly remove all
debris.
Page 5-2
200 BENCH PROCEDURES
Universal dial depth gauge PT5025, with a 3-inch
stylus extension PT5052-11, is recommended for
measuring the counterbore.
3. Measure and record the counterbore in four
places, 90 degrees apart. Using a depth
gauge with a 3-inch extension, mark the
shallowest point. Subtract the lowest
number from the highest number. This is the
minimum amount to be machined for
cleanup.
SETTING UP COUNTERBORE TOOL PT2210
WITH CUTTER PLATE PT2210-3A
Refer to Figure 5-1.
1. Loosen the two cutter bit hold-down
capscrews (9). Install cutter bit (11) into
cutter plate PT2210-3A (13) by turning the
cutter bit adjuster (10) counterclockwise.
Cutter bit face must be facing a clockwise
rotation cut.
Do not tighten the cutter bit hold-down cap (12).
The cutter point should not extend beyond the
outer edge of the cutter plate. If the cutter bit
does stick out, damage to the bit will occur when
installing counterbore tool onto cylinder block.
2. Install the cutter plate on the main shaft (15).
Use the large end of hex key wrench
PT2210-14 (18) to hold the cutter plate and
tighten securely. The hole in the side of the
cutter plate accepts the large end of the tool.
Do not allow the cutter bit (11) to touch the
cylinder sleeve bore wall.