Print Page | of 11 PACCAR Dealernet Chassis No: BD124325 Vehicle type: MX_EPA10-MX ENGINE F 1401 233500 051 035 repair height cylinder liner (Basic assy.) hupsieportal.paccar.com/dealernet/Rapido/Index.aspx?aid~2&cid=RapApp&role=-NA&... 11/17/2017Print Page 2 of 11 PACCAR Dealernet aj repair height cylinder liner Lo (Basic assy.) +1 repair height cylinder liner (Basie assy:) Di = 11 repair height eytinder liner (Basic assy.) Explanation Measure cylinder liner height This procedure describes the correct method for measuring the cylinder liner height in the event of cavitation, There are different service cylinder liners available to carrect the cylinder liner height. =A service cylinder liner with a 0.50 mm [0.020 in} higher collar. = A service cylinder liner with a 0.25 mm (0.0098 in} higher collar. = A service cylinder liner with a 0.04 mm [0.0016 in} higher collar. Conditions before repair The cylinder liner seat can only be repaired 1 2 when ‘The surface of the cylinder block deck (A) is not damaged or machined + The cavitated surface of the liner seat (B) is not deeper than 0.45 rm [0.0177 in] = The surface of the liner bore (C) is not cavitated hecking the repair possibility 1. Mark the position of the cylinder liners To install the eylinder liner in its ‘original orientation 2. Position the special too! (1) cylinder liner. 3. Check that the tool is properly centered and tighten the attachment bolts (2) in the specified sequence to the specified torque. 148) on the htips://eportal paccar.com/dealerneRapido/Index. aspx aid=2&cid=RapApp&role-NA®... 11/17/2017Print Page 3 of L1 Place the special tool (4) (1203047) onto the height measuremeht tool (1) 5. Fit the clock gauge (3) into the cylinder liner height gauge block (4) Use a digital clock gauge with an accuracy of 0.005 mm [0.0002 in} 6. Position the tip of the clock gauge (3) onto the outside edge of the cylinder liner. 7. Measure the cylinder liner height according to the specified measuring sequence and note the values in the table, Re-zero the clock gauge before each individual measurement. 8. Remove the special tool (1) (1809948) from the cylinder liner Remove the cylinder liner from the cylinder block according to the job: (Remove 4 (one) cylinder liner) ‘spect the cylinder block according to the ‘onditions before repair as described above. 11. Machine the surface of the liner seat until itis free of cavitation according to the procedure ‘epait cylinder liner sea} 412, Install the service cylinder liner. Make sure that the cylinder block is cleaned thoroughly 13. Repeat steps 2 to 7. 10. 14, Calculate how much supporting surface must bbe machined using the following calculation method hutps://eportal.pacear.com/dealernet/Rapido/Index.aspx?aid-2&eid=RapApp&role-NA®.... 11/17/2017Print Page 4 of L1 Calculating method mm: Repair cylinder 1. |Q=(X-0.015 mm)-¥ Repair cylinder |Q=(X-0.015 mm)-Z Repair cylinders 2, |Q=(X-0.015 mm).(0.5" 3, 4,5 Iev+z)) Calculating method inch (Q=(X-0.0008 in)-¥ ¥=(X-0.0006 in)-Z Repair cylinders 2, |Q=(X-0.0008 in}-(0.5" 3.4, 5 (vez) * Qs total machining depth * X= average cylinder liner height ((A*B+C+D+E+F)/6) * Y= average cylinder liner height from the adjacent liner ((C+A+F)/3) * Z= average cylinder liner height from the adjacent liner ((E+8+D)/3) = 0.015 mm [0.0006 in] = setting new cylinder liner ‘The difference between the average of E, B, DandC, A, F from the adjacent liner must not exceed 0.03 mm [0.00012 in} 15. Machine the supporting surface using this procedure: "Repair cylinder liner seat 040943 - 07, Repair cylinder liner seat This procedure describes the correct method of repairing the eylinder liner seat by machining ‘The following procedure is carried out using a cylinder liner seat repair toal (1961378) ic.w. cutting tool (1903051) Make sure that all openings are covered before machining the liner seat. Before the tool can be used, the adjacent cylinder liner(s) must be removed hutps:/eportal pacear. com/dealemet/Rapido/Index.aspx?aid=2&cid-RapApp&role-NA®.... 11/17/2017Print hutps://eportal,pacear. com/dealemet/Rapido/Index.aspx?aid~2&cid=RapA ppé&rol Page 5 of 11 Machining of the cylinder liner seat can only be done in two stages : 1. Stage one: Machine the cylinder liner seat until the surface is free of cavitation. 2. Stage two! Machine the oylinder liner seat until the calculated depth is reached. 4 turning handle 2 switch Tool overview 3 centering role 4 main spindle 5 cutting tool 6 horizontal feed bus 7 lacking bracket 8 magnet base 9 vernier Olocking screw ‘worm screw 12vertical feed bus 1. Keep the locking bracket up and mount the cutting tool ‘The serrated surface must face the electromagnet, and the centering roll must be directed towards the R on the spindle. 2. Position the tool so that itis slightly shifted from the center of the cylinder. Make sure th block and the tool are cleaned thoroughly. NA&... 11/17/2017Print Page 6 of 11 3. Set the switch to position 1 to activate the electromagnet. Screw the vertical feed bus Up $0 that the cutting tool freely passes over the cylinder liner seat 4. Press the locking bracket downwards, and place the centering roll against the wall of the cylinder liner seat, where the distance to the wall is greatest. Set the switch to position 0. Do not set the switch in position 2. Otherwise the magnetism fully disappears, aspx?aid=2&cid=RapApp&role=NA&.... 11/17/2017 hnups://eportal.pacear.com/dealernet/Rapido/IndesPrint 10. " 12, 13 Center the unit by holding the horizontal feed bus with two finger$, and turn the handle clockwise, The Unit now moves eccentrically with every revolution, = The eccentric movement decreases and finally stops as the centering roll moves back: = Release the horizontal feed bus at the right moment, when the centering roll is just slightly touching tne counterbore wall all around + Rotate counterciockwise when the centering roll loses contact with the counterwall, = ~ ‘When the tool is correctly centered, set the switch to position 1 Press the locking bracket downwards and position the cutting tool above the liner seat. Loosen the locking screw and slowly rotate the turning handle and vertical feed bus clockwise until the cutting tool touches the seat. Loosen the worm screw, set the vernier to 0 and tighten the warm screw again Press the locking bracket downwards and place the cutting tool before the seat Set the refacing depth by rotating the vertical feed bus, then tighten the locking screw. Start with 0.05 mm (0.002 in}. Do not exceed 0.16 mm [0.006 in] for the following steps, Rotate the turning handle clockwise while holding the horizontal feed bus. * Let the horizontal feed bus steadily slip between your fingers, = Never rotate the turning handle counterclockwise This damages the cutting tool, Continue until the cutting tool has machined the entire surface, Make sure that the entire surface is machined before setting the next depth hutps://eportal paccar.com/dealernev/Rapido/Index.aspx°aid Page 7 of 11 (30 pans 11/17/2017Print https://eportal.paccar.com/dealernevRapido/Index.aspx?aid=2&cid=RapApp&rok Page 8 of 11 14, Press the locking bracket downwards and place the cutting tool just before the seat. 15. Stage one: check if the surface of the liner Seat is free of cavitation. If not, repeat steps 11 to 14, Before the exact machining depth can be calculated, the liner seat must be free of cavitation 16, Stage two: Continue with steps 11 to 15 until the calculated depth is reached 17. When the calculated depth is reached, make. sure that the radius R 1.2 mm [0.047 in] is machined 18. Remove the tool 49. Clean the cylinder block and tool thoroughly. 20. Mark the cylinder block with an L and the number of the repaired cylinder on the DMC location. MO4I317 - 05.19.2016 Technical data Checking data, cylinder liner height Tighten to 60 Nm [443 Ib-n] in two phases in the specified sequence 1. Phase 1:25 Nm [221 losin) 2. Phase 2: 50 Nm [443 Ib-in} Tightening sequence special tool NAG... 11/17/2017Print Page 9 of 11 ‘ond phase only after completing first phase on all bolts. Cylinder liner height (X) 0.10 - 0.18 mm [0 0039 used cylinder liner ~0.0070 in] Cylinder liner neight (X) 0.12 - 0.18 mm [0.0048 new cylinder liner = 0.0070 in] 1 Cylinder liner 2 Cylinder block ‘The difference between B and A from the adjacent liner must not exceed Ui) 0.03 mm 0.0012 in} Al the readings must be within the Measuring sequence specified tolerances, huips://eportal,paccar.com/dealernevRapido/Index.aspsaid=2&cid=RapApp&role=NA&... 11/17/2017Print Page 10 of 11 Mo32175 - 07.21.2016 Special tools Special tool eategory: Mandatory special 1o0l for: NA region rBogsae Auxiliary tool for height measurement of cylinder liner > STIS09948 - 11.29.2011 Special tool category: Mandatory special tool for: NA region 1903047 Cylinder liner height gauge block. Supersedes 0694795 https://eportal. pacear.com/dealernet/Rapido/Index.aspx?aid=2&eid=RapA pp&role-NA&... 11/17/2017Print Page 11 of 11 ST1903047 + 09.17.2013 Special tool eategory: Recommended special tool 1903077 Cylinder liner seat repair tool i.c.w. 1903060 or 1903064 811903077 - 04.07, Di ‘Special tool eategory: Recommended special tool 1903061 Cutting tool 1.2 i.c.w. 1903077 or 1961378 NT ST1903061 ~ 09.02.2014 ‘This information applies exclusively to the entered chassis number or the selected engine type. Please take into account that this information may change daily. Therefore the provided information is only valid on 11-17-2017, You cannot derive any rights from the information provided with respect to vehicles and/or components of another series, with another chassis number, and/or of another date, (BD 124325 / MX_EPA 0) hitps://eportal.paccar.com/dealernet/Rapido/Index.aspx?aid=2&cid=RapApp&role=-NA&... 11/17/2017