5-101.bk Page 3 Friday, March 17, 2006 11:05 AM When the entire block must be counterbored, cut the deepest bores first. This way, the tool can be adjusted to the lowest depth and used for all cylinders, ensuring uniform depth on all cylinder counterbores. It may be necessary to use a flashlight to see the cutter bit adjusting screw. 11. Using hex key wrench PT2210-14 (18), turn the cutter bit adjusting screw clockwise until the cutter bit rests on the counterbore ledge. 3. Position the tool in the cylinder bore by backing the depth-set collars (5 and 16) off and lowering the cutter plate (13) into the counterbore to center the tool. 12.
If the cutter bit will not adjust, adjust the lower depth-set collar (16) 0.005 inch (0.127 mm) more and recheck cutter bit hold-down screws for looseness. 4. Secure the cutter plate to the cylinder block with four M16 x 2 x 90 hex-head capscrews (3) and special washers (4) from the counterbore tool kit PT2210. 13. Zero the depth-set collars: a. Back off the lower depth-set collar (16) and carefully lower the cutter plate (13) into the bore and allow the cutter to rest on the counterbore ledge. 5. Cross-torque the capscrews to 30 lb-ft (41 N m) using torque wrench J 24406 or equivalent. b. Rotate both depth-set collars (5 and 16) down until the bottom collar contacts the main housing (8).
Lift T-handle (2) slightly (so cutter plate is not in contact with the counterbore) and rotate the mainshaft (15) counterclockwise to ensure cutter plate turns freely without binding. If necessary, loosen the capscrews and relocate the tool. Do not force the collar beyond this point, as it will lift the cutter plate and prevent an accurate zero reading. 6. Using the counterbore tool T-handle (2), raise the cutter plate approximately 1/2 inch (12.7 mm) from the counterbore ledge. 14. Set the depth of the cut. Determine the final depth of the cut and back off the top depth- set collar accordingly.
Each increment on the depth-set collar increases the depth of the cut by one-thousandth (0.001) of an inch (0.025 mm). Tighten the thumbscrew (17) on the upper collar (5) securely. 7. Using hex key wrench PT2210-14 (18), turn the cutter bit adjusting screw (10) clockwise until the cutter bit contacts the counterbore ledge. Do not touch the counterbore wall. 8. Back off the lower depth-set collar (16) and lower the cutter plate until the cutter rests on the ledge. 9. Rotate the lower depth-set collar down until the collar contacts the main housing. 10. Rotate the collar an additional five increments: 0.005 inch (0.127 mm).
Each graduation of the collar is one-thousandth (0.001) of an inch (0.025 mm). This will lift the cutter bit 0.005 inch (0.127 mm) off the counterbore ledge, allowing an accurate setting of the cutter bit. Page 5-3 200 BENCH PROCEDURES