KENR8772

79

Testing and  Adjusting Section

Table 19

Specifications

0.05  to 0.13  mm

Liner Projection

(0.00197 to 0.00512 inch)

Maximum Variation in

Each Liner

0.03 mm (0.00118 inch)

Maximum Average

Variation Between

Adjacent Liners

0.03 mm (0.00118 inch)

0.03 mm (0.00118 inch)

Maximum Variation

Between All Six Liners

9.  If a liner does not meet the recommended cylinder

liner projection specification, check the following

parts:

•  The depth of the cylinder block bore should be

116.421 ± 0.027 mm (4.58349 ± 0.00106 inch).

g00286049

•  The liner flange should be 116.57 to 116.60 mm

(4.58936 to 4.59054 inch).

Illustration 66

Typical example

If the dimensions for  the liner flange do not

match the specifications, replace the liner. Then

repeat the liner projection measurements. If the

dimensions for the depth of the  cylinder block

bore do not match the specifications, replace the

cylinder block. Then repeat the liner projection

measurements.

1.  Install Tooling (A). Refer to illustration 66. Always

put a force on the crankshaft in the same direction

before the dial indicator is read. This will remove

any crankshaft end clearance.

2.  Set the dial indicator to read 0.0 mm (0.00 inch).

3.  Turn the flywheel at intervals of 45 degrees and

read the dial indicator.

i04032190

Flywheel - Inspect

4.  Take the measurements at all four points. The

difference between the lower measurements and

the higher measurements that are performed at

all four points must not be more than 0.20  mm

(0.008 inch), which is the maximum permissible

face runout (axial eccentricity) of the flywheel.

Face Runout (Axial Eccentricity) of

the Flywheel

Bore Runout (Radial Eccentricity)

of the Flywheel

Table 20

Required Tools

Table 21

Tool

Part Number

21825617

-

Part Description

Dial Gauge

Qty

1

Required Tools

A

Tool

Part Number

21825617

-

Part Description

Dial Gauge

Qty

1

Holder

1

A

Magnetic Base

1

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80

KENR8772

Testing and  Adjusting Section

i04032193

Flywheel Housing - Inspect

Table 22

Required Tools

Part Number        Part Description

Tool

Qty

21825617

-

Dial Gauge

Holder

1

A

Face Runout (Axial Eccentricity) of

the Flywheel Housing

g01278054

Illustration 67

Typical example

1.  Install Tooling (A). Refer to illustration 67.

2.  Set the dial indicator to read 0.0 mm (0.00 inch).

3.  Turn the flywheel at intervals of 45 degrees and

read the dial indicator.

4.  Take the measurements at all four points. The

difference between the lower measurements and

the higher measurements that are performed at

all four points must not be more  than 0.20 mm

(0.008 inch) for the maximum permissible face

runout (radial eccentricity) of the flywheel.

g00285931

Illustration 69

Typical example

If you use any other method except the method that

is given here, always remember that the  bearing

clearance must be removed in order to receive the

correct measurements.

1.  Install Tooling (A) to the flywheel so the anvil of the

dial indicator will contact the face of the flywheel

housing. Refer to illustration 69.

2.  Use a rubber mallet and tap the crankshaft toward

the rear before the dial indicator is read at each

point.

g00286058

Illustration 68

Flywheel clutch pilot bearing bore

5.  To find the runout (eccentricity) of the pilot bearing

bore, use the preceding procedure.

6.  The runout (eccentricity) of the bore for the pilot

bearing in the flywheel must not exceed 0.13 mm

(0.005 inch).

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KENR8772

81

Testing and  Adjusting Section

g00285932

g00285932

Illustration 70

Illustration 72

Checking face runout of the flywheel housing

Checking bore runout of the flywheel housing

3.  Turn the flywheel while the dial indicator is set at

0.0 mm (0.00 inch) at location (A). Read the dial

indicator at locations (B), (C), and (D).

2.  Turn the flywheel while the dial indicator is set at

0.0 mm (0.00 inch) at location (A). Read the dial

indicator at locations (B), (C), and (D).

4.  The difference between the lower measurements

and the higher measurements that are performed

at all four points must not be more than 0.3 mm

(0.01181 inch), which is the maximum permissible

face runout (axial eccentricity) of  the flywheel

housing.

3.  The difference between the lower measurements

and the higher measurements that are performed

at all four points must not be more than 0.3 mm

(0.01181 inch), which is the maximum permissible

face runout (axial eccentricity) of  the flywheel

housing.

Bore Runout (Radial Eccentricity)

of the Flywheel Housing

i04201129

Crankshaft Thrust - Measure

Table 23

Required Tools

Tool

Part

Number

Part Description

QTY

A

21825617

Dial Indicator

Group

1

A thrust washer is installed on either side of the rear

main bearing. The thrust washer controls the  end

play of the crankshaft.

g00285934

Illustration 71

Force the crankshaft toward the front of the engine

and back to the rear of the engine.

Typical example

1.  Install Tooling (A) to the flywheel so the anvil of the

dial indicator will contact the bore of the flywheel

housing. Refer to illustration 71.

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KENR8772

Testing and  Adjusting Section

g02390536

g02390556

Illustration 73

Illustration 74

Typical example

Typical example

1.  Check the end play of the crankshaft with Tooling

(A).

2.  Use Tooling (A) to measure the backlash between

the camshaft gear (1) and the upper idler gear (2).

Refer to Specifications, “Gear Group (Front)” for

the backlash measurement.

2.  To check the tolerance of the crankshaft end play,

refer to Specifications, “Crankshaft”.

i04201149

Gear Group - Inspect

Table 24

Required Tools

Tool

Part

Part Description

QTY

Number

A

21825617

Dial Indicator

Group

1

Note: If one or more of the gears need to be removed

for repair, refer to Disassembly and Assembly, “Gear

Group (Front) - Remove” in  order to remove the

gears. Refer to Disassembly and Assembly, “Gear

Group (Front) - Install” in order to install the gears.

g02390558

Illustration 75

Typical example

1.  Inspect the gears for wear or for damage. If the

gears are worn or damaged, use new parts  for

replacement.

3.  Use Tooling (A) to measure the backlash between

the upper idler gear (2) and the lower idler gear

(3). Refer to Specifications, “Gear Group (Front)”

for the backlash measurement.

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KENR8772

83

Testing and  Adjusting Section

g02390559

g02317733

Illustration 76

Illustration 77

Typical example

Typical example

(1) Bolts

(2) Bolts

(3) Vibration damper

(4) Crankshaft pulley

(5) Crankshaft adapter

4.  Use Tooling (A) to measure the backlash between

the lower idler gear (3) and the crankshaft gear

(4). Refer to Specifications, “Gear Group (Front)”

for the backlash measurement.

Damage to the vibration damper  or failure of the

vibration damper will increase vibrations. A damaged

vibration damper will  result in damage to  the

crankshaft.

i04112355

Vibration Damper - Check

Replace the damper if any of the following conditions

exist:

NOTICE

•  The damper is dented or cracked.

Inspect the viscous vibration damper for signs of leak-

ing and  for  signs of  damage to  the case.  Either of

these conditions can cause the weight to  contact the

case. This contact can affect damper operation.

•  The paint on  the damper is discolored from

excessive heat.

•  The damper is bent.

•  The bolt holes are worn or there is a loose fit for

the bolts.

•  The engine has had a crankshaft failure  due to

torsional forces.

Check the areas around the holes for  the bolts in

the vibration damper for cracks or for wear and for

damage.

Use the following  steps in order to check  the

alignment and the runout of the vibration damper:

1.  Remove any debris from the front face of  the

vibration damper. Remove any debris from the

circumference of the vibration damper.

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KENR8772

Testing and  Adjusting Section

2.  Mount the dial indicator on the front cover. Use

the dial indicator to measure the outer face of the

vibration damper. Set the dial indicator to read

0.00 mm (0.00 inch).

3.  Rotate the crankshaft at intervals of 45 degrees

and read the dial indicator.

4.  The difference between the lower measurements

and the higher measurements that are read on the

dial indicator at all four points must not be more

than 0.0127 mm (0.0005 inch).

If the reading on the dial indicator is  more than

0.0127 mm (0.0005 inch), inspect the pulley and

the vibration damper for damage. If the pulley or

the vibration damper are damaged, use new parts

for replacement.

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KENR8772

85

Testing and  Adjusting Section

Electrical System

Alternator - Test

i02418531

1.  Put the positive lead “+” of a suitable multimeter

on the “B+” terminal of  the alternator. Put the

negative “-” lead on the ground terminal or on the

frame of the alternator. Put a suitable ammeter

around the positive output wire of the alternator.

2.  Turn off all electrical accessories. Turn off the fuel

to the engine. Crank the engine for 30 seconds.

Wait for two minutes in order to cool the starting

motor. If the electrical system appears to operate

correctly, crank the engine again for 30 seconds.

Note: Cranking the engine for 30 seconds partially

discharges the batteries in order to do a charging

test. If the battery has a low charge, do not perform

this step. Jump start the engine or charge the battery

before the engine is started.

3.  Start the engine and run the engine at full throttle.

4.  Check the output current of the alternator. The

initial charging current should be  equal to the

minimum full load current or  greater than the

minimum full load current. Refer to Specifications,

“Alternator and Regulator” for the correct minimum

full load current.

Table 25

Fault Conditions  And Possible  Causes

Current At Start-up

The Voltage  Is Below

Specifications After 10

Minutes.

The Voltage  Is Within

Specifications After 10

Minutes.

The Voltage  Is Above

Specifications After 10

Minutes.

-

Less  than  the

specifications

Replace the  alternator.

Check the  circuit of the

ignition switch.

Turn on all accessories. If the

voltage decreases below the

specifications, replace the

alternator.

Decreases after matching

specifications

Replace the alternator.

The alternator and the battery   Replace the alternator.

match the specifications.

Turn on all accessories  in

order to verify that the voltage

stays within specifications.

The voltage consistently

exceeds specifications.

Test the battery.  Test the

alternator again.

The alternator  operates           Replace  the alternator.

within the specifications. Test    Inspect the  battery for

the battery.

damage.

5.  After approximately ten minutes of operating the

engine at full throttle, the output voltage  of the

alternator should be 14.0 ± 0.5 volts for a 12 volt

system and 28.0 ± 1 volts for a 24  volt system.

Refer to the  Fault Conditions And Possible

Causes in Table 25.

6.  After ten minutes of engine operation, the charging

current should decrease to approximately  10

amperes. The actual  length of time for the

decrease to 10 amperes depends on the following

conditions:

•  The battery charge

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KENR8772

Testing and  Adjusting Section

•  The ambient temperature

•  The speed of the engine

Test the charging unit and the voltage regulator on

the engine. Use wiring and components that are a

permanent part of the system. This testing will give an

indication of needed repair. After repairs are made,

perform a test in order to prove that the units have

been repaired to the original condition of operation.

Refer to the  Fault Conditions And Possible

Causes in Table 25.

To check for correct output of the alternator, refer to

Specifications.

i02801089

Battery - Test

Before the start of on-engine testing, the charging

system and the battery must be checked according

to the following steps.

Most of the tests of the electrical system can be done

on the engine. The wiring insulation must be in good

condition. The wire and cable connections must be

clean, and both components must be tight.

1.  The battery must be at least 75 percent (1.225

Sp) of the full charge. The battery must be held

tightly in place. The battery holder must not put

too much stress on the battery.

2.  Cables between the battery, the starter, and the

engine ground must be the correct  size. Wires

and cables must be free of corrosion. Wires and

cables must have cable support clamps in order to

prevent stress on battery connections (terminals).

Never disconnect any charging unit circuit or bat-

tery circuit cable from the battery when the charg-

ing unit is operated. A spark can cause an explo-

sion from the flammable  vapor mixture of hydro-

gen and  oxygen  that is  released from  the  elec-

trolyte through  the battery outlets.  Injury to per-

sonnel can be the result.

3.  Leads, junctions, switches, and panel instruments

that have direct relation to the  charging circuit

provide correct circuit control.

4.  Inspect the drive components for the charging unit

in order to be sure that the components are free of

grease and oil. Be sure that the drive components

have the ability to operate the charging unit.

The battery circuit is an electrical load on the charging

unit. The load is variable because of the condition of

the charge in the battery.

NOTICE

The charging unit will be damaged if the connections

between the battery and the charging unit are broken

while the  battery is  being charged.  Damage occurs

because the load from the battery is lost and because

there is an increase in charging voltage. High voltage

will damage the charging unit, the regulator, and other

electrical components.

i04112391

Electric Starting System - Test

Most of the tests of  the electrical system can be

done on the engine. The wiring insulation must be

in good condition. The wire and cable connections

must be clean, and both components must be tight.

The battery must be fully charged. If the on-engine

test shows a defect in a  component, remove the

component for more testing.

i04112370

Charging System - Test

The starting system consists of the following  four

components:

Note: This procedure is only applicable if a charging

system is installed.

•  Keyswitch

The condition of charge in the battery at each regular

inspection will indicate whether the charging system

operates correctly. An adjustment is necessary when

the battery is constantly in a low condition of charge

or a large amount of water is needed.

•  Start relay

•  Starting motor solenoid

•  Starting motor

This document is printed from SPI². Not for RESALE