NUMBER: S.M. REF.: Listed in Table ENGINE: Series 50/50G DATE: October 2013 SUBJECT: MACHINING CYLINDER BLOCK COUNTERBORES

Transcription

1 NUMBER: S.M. REF.: Listed in Table ENGINE: Series 50/50G DATE: October 2013 SUBJECT: MACHINING CYLINDER BLOCK COUNTERBORES ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change DDC-SVC-MAN-0028 Series 50 / 50G Machining Cylinder Block This is a new section. Counterbores Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

2 MACHINING CYLINDER BLOCK COUNTERBORES Cutter plate assembly (J 41063) is used with Porta-Matic boring tool (PT 2050 D) to machine cylinder block counterbores for the installation of repair bushings. J features a special diameter and taper design which will permit the machining of the counterbore area in accordance with Detroit specifications. Use the appropriate Detroit part when installing the counterbore insert (repair bushing). Counterbore insert part number can be located in AP Rev. Machine the cylinder block counterbores as follows: 1. Ensure block deck surface and boring tool base plate are clean and burr-free. 2. Plug the push tube opening, oil galleys and lower liner packing areas to seal out any contaminating particles. Ensure cutter is marked Series 50. Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined. 3. Using cutter (PT ), set to the dimensions listed in Table 1 and see Figure 1. Area to be Machined Cutter Setting Dimensions Depth of Cut Upper counterbore ± mm (6.370 ±.0005 in. Diameter) mm (.602 in.) Table 1 PT Cutter Dimensions Figure 1 Bushing Repair Area

3 4. Assemble Cutter Plate (PT 2090) to the Porta-Matic mainshaft. See Figure 2. Figure 2 Cutter Plate (PT 2090) Location 5. Mount the Porta-Matic over cylinder to be bored. Open feed valve to lower cutter plate into cylinder bore. Push down firmly while rotating the mainshaft to insure proper alignment of Porta-Matic. 6. With the cutter plate centered in the cylinder bore, align the base plate with the four cylinder head bolt holes in the block deck while maintaining as much base plate-to-block deck contact as possible. 7. Cross-torque all four cylinder head bolts slowly to 67 N m (50 lb ft). Rotate mainshaft to insure that the cutter plate is centered and moves freely. If binding occurs, loosen the four cylinder head bolts and repeat steps 6 and Pull up on the mainshaft to retract the cutter plate to the highest position and close the feed valvetolockinposition. NOTICE: Ensure cutter bit is completely inserted into cutter slot. 9. Insert cutter into slot of cutter plate. Hold cutter bit against the main shaft of the boring tool and tighten the cutter plate set screw to secure the cutter.

4 10. Slowly lower the cutter and allow to rest onto engine block deck surface. Insert a mm (0.004 in.) shim between cutter and engine block. Set the depth of cut using bushing (PT 8065). Tighten socket set screw to hold depth collar in place. See Figure 3. Figure 3 Upper Counterbore Cutting Area 11. Retract cutter plate to the up position and lock machine. 12. Attach a right angle drill (PT 7145 A) and proceed to bore hole until Porta Matic freewheels. 13. Open feed valve and retract cutter plate upward. Remove cutter bit. 14. Repeat steps 5 to 13 for each of the next three bores. 15. Cut the counterbore ledge depth to ± mm (0.353 ± in.) using counterbore tool (PT 2250 B) and the appropriate cutter plates. Follow normal ledge cutting procedures to achieve the finished counterbore depth.

5 MACHINING CYLINDER BLOCK COUNTERBORES USING SHIMS Cutter plate assembly (J 41065) is used with Counterbore tool (PT 2250 B) to machine cylinder block counterbores for the installation of repair shims. Use the appropriate Detroit part when installing the counterbore shims. Counterbore shim part numbers can be located in 11TS-8Rev. 1. Cylinder Block 2. Cylinder Liner Protrusion 3. Cylinder Liner Figure 4 Cylinder Liner Protrusion 1. Remove cylinder head. Refer to section. 2. Remove oil pan. Refer to section. 3. Remove cylinder liner. Refer to section. 4. Ensure block deck surface and boring tool base plate are clean and free of burrs. 5. Plug all open areas of the engine compartment to seal out any contaminating particles. Ensure cutter is marked Series 50. Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined. 6. Retract the cutting bit into the cutting plate. 7. Mount the counterbore cutting tool over the cylinder to be machined. Install mounting bolts into the appropriate cylinder head bolt holes, leaving the bolts loose.

6 8. Lower the cutting plate (2) to rest in the cylinder bore (1) and rotate the T-handle to center the tool. Figure 5 Cutter Plate (PT 2090) Location 9. Torque the two opposing mounting bolts to 68 N m (50 lb ft). Verify that the tool is still centered in the bore. If not, then loosen bolts and re-center the tool. If centered, torque the two remaining mounting bolts to 68 N m (50 lb ft). 10. Raise the tapered cutting head from the block and insert the spacer block. While there is no load on the tool, extend the cutter bit outward (using a clockwise rotation of the cutting bit screw) until it just touches a 0.15 mm (0.005 in.) feeler gauge or shim placed next to the vertical wall of the counterbore. Tighten the Allen head hold-down screws. Figure 6 Spacer Block PT Remove the spacer block and slowly lower the cutting head into the counterbore. (Be careful not to damage the cutting bit).

7 12. Adjust the lower locking collar downward until it comes in contact with bronze bushing, and the cutter bit is not resting on lower surface of counterbore. Rotate the T-handle to ensure there is no binding or scraping of the counterbore walls. If so, adjust cutting bit. 13. Slowly back off the lower locking collar until the cutting bit is just touching the lower surface of the counterbore. 14. Set the depth of the cut by using the repair shim. Insert the shim between the locking collars, lower the upper lock collar down until it comes in contact with the shim. Tighten the thumb screwonthetopcollar. If cutting more than one counterbore, the shim used to set the depth of the cut in each cylinder must be used in that cylinder. Failing to do so may increase/decrease the liner protrusion. 15. Lubricate the tool bushings. Back-off the lower collar by two graduations, mm ( in.). Rotate the T-handle clockwise with moderate, constant pressure, stopping at random positions to prevent creating a ridge in the counterbore. Continue backing-off the lower collar, two graduations at a time, until the collars come together. 16. Raise the cutting tool from the counterbore and insert depth spacer. 17. Retract the cutting bit into the cutting plate to protect the bit. 18. Remove the cutting tool from engine. 19. Remove all protective material used to seal out any contaminating particles and clean any/all areas that were not protected. 20. Place the shim on the lower ledge of the counterbore. 21. Insert the cylinder liner and measure liner protrusion. Refer to section. 22. Install the cylinder liner. Refer to section. 23. Install the cylinder head. Refer to section. 24. Install the oil pan. Refer to section.

8 ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. Detroit Diesel, DDC, Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Copyright 2013 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.