REPAIR INSTRUCTIONS
Page 141
CUTTING THE COUNTERBORE
Refer back to Figure 128.
1. Fill the oil fill tube (7) with 30W nondetergent
oil to maintain lubrication during use.
2. Back off the lower depth-set collar (16) two
increments or less, and tighten the
thumbscrew (6) securely.
3. Cut the counterbore by turning the T-handle
clockwise while maintaining constant
downward pressure on the tool. Stop the
handle in a different position to avoid
creating a ridge in the counterbore.
4. Continue backing off the lower depth-set
collar, no more than two graduations per cut.
Check the depth measurement between
each adjustment. Plan to remove 0.001 inch
(0.025 mm) on the final cut to meet the final
predetermined counterbore depth. This
ensures achieving a very fine machined
finish.
5. Remove the tool from the cylinder bore.
a. Loosen the two cutter bit hold-down
capscrews (9) and rotate the cutter bit
adjusting screw (10) counterclockwise
until the cutter bit is retracted into the
cutter plate (13).
b. Remove the four machine hold-down
bolts (3) and special washers (4).
c. Remove the tool from the cylinder bore.
6. Follow steps 1 through 5 for the remaining
cylinders.
COUNTERBORE DEPTH MEASUREMENT
Measure the counterbore depth (Figure 129) and
calculate the number of shims (part Nos.
505GC26P2, P3, P4, P10, P12 and P14) needed
to obtain proper cylinder sleeve flange height.
The shim “P” number signifies shim thickness,
i.e., P14 is 0.014-inch thick. When installing
shims, always use the thickest shims and the
least amount of shims as possible to obtain the
proper sleeve flange height.
The standard production counterbore depth has
been changed from 4.000–4.004 inches to
3.998–4.002 inches.
129
Figure 129 — Counterbore Depth Measurement
5_106_00.bk Page 141 Friday, August 4, 2000 11:17 AM
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