NUMBER: 1 34 13 S.M. REF.: Listed in Table ENGINE: EPA04/07 Series 60 DATE: January 2013 SUBJECT: CHECKING CYLINDER LINER PROTRUSION ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Checking Cylinder Liner Added Link DDC-SVC-MAN-0004 EPA04 Series 60 Protrusion Additional Information Altered steps, Added link DDC-SVC-MAN-0005 EPA07 Series 60 Installation of Cylinder Liner Additional Information Added Link Altered steps, Added link Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
THE FOLLOWING APPLIES TO DDC-SVC-MAN-0004
CHECKING CYLINDER LINER PROTRUSION Check as follows: 1. Wipe the inside and outside of the liner clean. Be sure the block bore and counter bore are clean, so the liner flange will seat properly. The block counter bore depth must be 8.9255 to 8.9662 mm (0.3514 to 0.3530 in) and must not vary more than 0.04 mm (0.0016 in) in depth around the circumference. Variation between two adjacent block counter bores may not range in depth more than 0.0508 mm (0.002 in) when measured in the center line of block. Specifications are listed in Table. 1. Cylinder Block A. Counterbore Depth Measurement Figure 1 Measuring Counterbore Depth Thoroughly clean the cylinder block liner counter bores to remove any foreign material. Foreign material in the cylinder liner counter bores can cause the liner to seat improperly. 2. Install the cylinder liner into the engine block without any seals. It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is measured.
3. Install J 35597 A, over the liner. See Figure 2. Figure 2 Cylinder Liner Installation Tools 4. Thread three cylinder head bolts through the tool and into a head bolt hole so that the round shoe of the tool is centered over the liner. It is not necessary to torque the bolts. 5. Tighten the bolts. 6. Turn the threaded center bolt in a clockwise direction. As the round shoe of the tool reaches the liner, ensure that the shoe is properly positioned into the cylinder liner. 7. Continue turning the bolt until the liner bottoms in the cylinder counterbore. Apply a tightening torque of 60 N m (44 lb ft) to the installation tool center bolt. 8. Install a dial indicator sled gage. See Figure 2.
9. Measure the distance from the top of the liner flange to the top of the block. See Figure 3. Figure 3 Cylinder Liner Protrusion [a] [b] Allowable liner protrusion is -0.0127 to 0.0762 mm (-0.0005 to 0.003 in) with no more than 0.0508 mm (0.002 in) variation between any two adjacent cylinders. Specifications are listed in Table. If the liner protrusion exceeds the maximum allowable, remove the liner and check for debris under the liner flange. If there is no debris, machine the liner counterbore. Refer to section Additional Information.
ADDITIONAL INFORMATION SHOP NOTES Shop notes contains information on checking bearing clearances, the crankshaft remanufacturing procedures and a glossary. CYLINDER BLOCK LINER BORING Further information will be printed as it is developed. 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 41063 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 AP2005-048Rev. Machine the cylinder block counterbores as follows: 1. Ensure block deck surface and boring tool base plate are clean and burr free. 2. Plug push tube opening, oil galleys and lower liner packing areas to seal out any contaminating particles. Ensure cutter is marked Series 60. Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined.
3. Using cutter (PT 2000 109) set to the dimensions listed in Table 2 and see Figure 13. Table 1 Area to be Machined Cutter Setting Dimensions Depth of Cut Upper counterbore 161.798 ± 0.0127 mm (6.370 ±.0005 in. Diameter) PT 2000 109 Cutter Dimensions 15.29 mm (.602 in.) Figure 4 Bushing Repair Area 4. Assemble Cutter Plate (PT 2090) to the Porta-Matic mainshaft. See Figure 14. Figure 5 Cutter Plate(PT 2090) Location 5. Mount 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 cutter plate centered in the cylinder bore, align base plate with the four cylinder head bolt holes in 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 8 and 9. 8. 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. 10. Slowly lower the cutter and allow to rest onto engine block deck surface. Insert a 0.1016 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 15. Figure 6 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 five bores. 15. Cut the counterbore ledge depth to 8.966 ± 0.0254 mm (0.353 ± 0.001 in.) using counterbore tool (PT 2250 B) and the appropriate cutter plates. Follow normal ledge cutting procedures to achieve the finished counterbore depth. 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. See Figure 7. 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 7 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 60. Maintainasharpcutterbit 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.
8. Lower the cutting plate (2) to rest in the cylinder bore (1) and rotate the T-handle to center the tool. See Figure 8. Figure 8 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 9 Spacer Block PT 2200 83 11. Remove the spacer block and slowly lower the cutting head into the counterbore. (Be careful not to damage the cutting bit).
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, 0.0254 mm (0.0001 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.
THE FOLLOWING APPLIES TO DDC-SVC-MAN-0005
INSTALLATION OF CYLINDER LINER Install as follows: Refer to section for 14L liner, piston and connecting rod procedure. 1. Wipe the inside and outside of the liner clean. Be sure the block bore and counter bore are clean, so the liner flange will seat properly. The block counter bore depth must be 8.9255 to 8.9662 mm (0.3514 to 0.3530 in.) and must not vary more than 0.04 mm (0.0016 in.) in depth around the circumference. No two adjacent block counter bores may range in depth more than 0.025 mm (0.001 in.) when gaged along the longitudinal cylinder block centerline. Specifications are listed in Table, and listed in Table. Thoroughly clean the cylinder block liner counter bores to remove any foreign material. Foreign material in the cylinder liner counter bores can cause the liner to seat improperly. 2. Lubricate the seal rings and crevice seal with clean petroleum jelly. 3. Install two new seal rings and a new crevice seal into their respective grooves in the liner. 4. Install the cylinder liner, piston and rod assembly into the cylinder bore. Refer to section 5. Install J 35597 A, over the liner. See Figure 10. It is necessary to leave the cylinder liner installation tool in place until after the liner protrusion is measured. Figure 10 Cylinder Liner Installation Tools 6. Thread three cylinder head bolts through the tool and into a head bolt hole, so that the round shoe of the tool is centered over the liner. 7. Tighten the bolts.
It is not necessary to torque the bolts. 8. Turn the threaded center bolt in a clockwise direction. As the round shoe of the tool reaches the liner, ensure that the shoe is properly positioned into the cylinder liner. 9. Continue turning the bolt until the liner bottoms in the cylinder counterbore. Apply a tightening torque of 60 N m (44 lb ft) to the installation tool center bolt. 10. Install a dial indicator sled gage. See Figure.
11. Measure the distance from the top of the liner flange to the top of the block. See Figure 11 [a] Allowable liner protrusion is -0.0127 to 0.0762 mm (-0.0005 to 0.003 in.) with no more than 0.0508 mm (0.002 in.) variation between any two adjacent cylinders. Specifications are listed in Table. [b] If the liner protrusion exceeds the maximum allowable, remove the liner and check for debris under the liner flange. [c] c. If the liner protrusion does the meet the minimum allowable, remove the liner and machine the counterbore. Refer to Additional Information. Figure 11 Cylinder Liner Protrusion
ADDITIONAL INFORMATION SHOP NOTES Shop notes contains information on checking bearing clearances, the crankshaft remanufacturing procedures and a glossary. CYLINDER BLOCK LINER BORING Further information will be printed as it is developed. 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-41063 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 AP2005-048Rev. Machine the cylinder block counterbores as follows: 1. Ensure block deck surface and boring tool base plate are clean and burr-free. 2. Plug all open areas of the engine compartment to seal out any contaminating particles. Ensure cutter is marked Series 60. Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined. 3. Verify that the Micrometer block is within specifications. Insert the setting standard with the side stamped UP between the cutter stop and the spindle. Hold the setting standard firmly; turn the micrometer thimble until the micrometer spindle is in contact with the setting standard. Does the micrometer read 5.000 inches? [a] Yes,gotostep5. [b] No, the micrometer will need to be calibrated. Go to step 4.
4. To calibrate the Micrometer, loosen the set screw and move the micrometer to read 5.000 inches. Slide the spindle to fit snug against the setting standard; tighten the set screw. Back off the micrometer and recheck the reading. If it does not read 5.000 inches, readjust again and recheck. See Figure 12. 1. Cutter Stop 4. Thimble 2. Spindle 5. Setting Standard 3. Set Screw 6. Micrometer Figure 12 Micrometer 5. Using cutter (PT 2000 109) set to the dimensions listed in Table 2 and see Figure 13. Area to be Machined Cutter Setting Dimensions Depth of Cut Upper counterbore 161.798 ± 0.0127 mm (6.370 ±.0005 in. Diameter) 15.29 mm (.602 in.) Table 2 PT 2000 109 Cutter Dimensions Figure 13 Bushing Repair Area
6. Assemble Cutter Plate (PT 2090) to the Porta-Matic mainshaft. See Figure 14. Figure 14 Cutter Plate (PT 2090) Location 7. Mount 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. 8. With cutter plate centered in the cylinder bore, align base plate with the four cylinder head bolt holes in block deck while maintaining as much base plate to block deck contact as possible. 9. 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 7 through 9. 10. Pull up on the mainshaft to retract the cutter plate to the highest position and close the feed valve to lock in position. NOTICE: Ensure cutter bit is completely inserted into cutter slot. 11. Insert cutter into slot of cutter plate. Hold cutter bit against the main shaft of the boring tool and tighten the cutter plate set screwtosecurethecutter.
12. Slowly lower the cutter and allow to rest onto engine block deck surface. Insert a 0.1016 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 15. Figure 15 Upper Counterbore Cutting Area. 13. Retract cutter plate to the UP position and lock machine. 14. Attach a right angle drill (PT 7145 A) and proceed to bore hole until Porta Matic freewheels. 15. Open feed valve and retract cutter plate upward. Remove cutter bit. 16. Repeat steps 7 to 15 for each of the next five bores. 17. Cut the counterbore ledge depth to 8.966 ± 0.0254 mm (0.353 ± 0.001 in.) using counterbore tool (PT 2250 B) and the appropriate cutter plates. Follow normal ledge cutting procedures to achieve the finished counterbore depth. 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. See Figure 16. 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 Protrusion 3. Cylinder Liner Figure 16 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 60. 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.
8. Lower the cutting plate (2) to rest in the cylinder bore (1) and rotate the T-handle to center the tool. See Figure 17. Figure 17 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 18 Spacer Block PT 2200 83 11. Remove the spacer block and slowly lower the cutting head into the counterbore. (Be careful not to damage the cutting bit).
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 screw on the top collar. 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, 0.0254 mm (0.0001 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.
ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. TM Detroit, 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.