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Page 5-2
200 BENCH PROCEDURES
[211 DB] CYLINDER BLOCK
Cylinder Sleeve Counterbore
SPECIAL TOOLS REQUIRED:
앫
Counterbore Tool PT2210
앫
Counterbore Cutter Plate PT2210-3A
앫
Universal Dial Depth Gauge PT5025
앫
Stylus Extension (3-Inch) PT5052-11
앫
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.
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.
5-101.bk Page 2 Friday, March 17, 2006 11:05 AM
Summary of Contents for E7
Page 1: ...E7 ENGINE OVERHAUL AUGUST 1997 ENGINE 5 101...
Page 2: ...Page 0 front fr5 Page 0 Friday March 17 2006 11 04 AM...
Page 5: ...E7ENGINE OVERHAUL MARCH 2006 2 5M REP AUGUST 1997 10M MACK TRUCKS INC 1997 ENGINE 5 101...
Page 13: ...ABOUT THIS MANUAL Page ix ABOUT THIS MANUAL front fr5 Page ix Friday March 17 2006 11 04 AM...
Page 15: ...TABLE OF CONTENTS Page xi TABLE OF CONTENTS front fr5 Page xi Friday March 17 2006 11 04 AM...
Page 24: ...Page xx NOTES front fr5 Page xx Friday March 17 2006 11 04 AM...
Page 31: ...200 SPECIFICATIONS Page 2 1 SPECIFICATIONS 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 55: ...200 ENGINE REMOVAL Page 3 1 ENGINE REMOVAL 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 58: ...Page 3 4 NOTES 5 101 bk Page 4 Friday March 17 2006 11 05 AM...
Page 90: ...Page 4 32 NOTES 5 101 bk Page 32 Friday March 17 2006 11 05 AM...
Page 91: ...200 BENCH PROCEDURES Page 5 1 BENCH PROCEDURES 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 158: ...Page 5 68 NOTES 5 101 bk Page 68 Friday March 17 2006 11 05 AM...
Page 159: ...200 ENGINE ASSEMBLY Page 6 1 ENGINE ASSEMBLY 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 240: ...Page 6 82 NOTES 5 101 bk Page 82 Friday March 17 2006 11 05 AM...
Page 272: ...Page 8 10 NOTES 5 101 bk Page 10 Friday March 17 2006 11 05 AM...
Page 273: ...200 TROUBLESHOOTING Page 9 1 TROUBLESHOOTING 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 292: ...Page 9 20 NOTES 5 101 bk Page 20 Friday March 17 2006 11 05 AM...
Page 293: ...200 APPENDIX Page 10 1 APPENDIX 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 295: ...200 APPENDIX Page 10 3 E7 LUBRICATION SYSTEM 5 101 bk Page 3 Friday March 17 2006 11 05 AM...
Page 296: ...Page 10 4 200 APPENDIX E7 COOLING SYSTEM 5 101 bk Page 4 Friday March 17 2006 11 05 AM...
Page 297: ...INDEX Page 11 1 INDEX INDEX FR5 Page 1 Friday March 17 2006 11 04 AM...
Page 302: ...Page 11 6 NOTES INDEX FR5 Page 6 Friday March 17 2006 11 04 AM...
Page 303: ...E7 ENGINE OVERHAUL PRINTED IN U S A ENGINE 5 101 MACK TRUCKS INC 1997...