a 8–1 SPECIFICATIONS

8–1.1

8–1.2

NOTE:There is a 0.030 in. (0,762 mm) x 0.148/0.152 in. (3,759/3,861 mm) steel insert fitted into the top groove and located immediately above the top compression ring. Do not remove this insert.

8–1.4 Piston Rings

The above ring gap is for a bore diameter of 3.125 in. (79,38 mm). Where the bore diameter is greater than this, the ring gap will be greater and for every 0.001 in. (0,03 mm) increase to the above bore diameter, 0.003 in. (0,08 mm) should be added to the quoted ring gap.

8–1.6 Connecting Rod Alignment

Large and small end bores must be square and parallel with each other within the limits of ± 0.010 in. (0,25 mm) measured 5 in. (127 mm) each side of the axis of the rod on test mandrel as shown in Fig. 1. With the small end bushing installed the limit of ± 0.010 in. (0,25 mm) is reduced to ± 0.0025 in. (0,06 mm).

Crankshaft

NOTE:This crankshaft is hardened by the Tuffride process. When regrinding, only very light cuts should be taken, especially in the region of the fillet radii and adequate cooling should be ensured during grinding operations. After regrinding the crankshaft it should be crack–detected and de–magnetized, then retreated by this Tuffride process after which the crankshaft should again be crack–detected and de–magnetized. Where facilities are not available to re–harden the crankshaft by this process, a factory replacement crankshaft should be obtained. Fillet radii andsurface finish must be maintained during crankshaft regrinding. Length of No. 3 main journal not to exceed 1.516 in. (38,506 mm) after regrinding. Where necessary, use oversize thrust washers to bring crankshaft end float within the correct limits.

8–1.8

Crankshaft Thrust Washers

Backed –– Lead Bronze Faced

Rear Main Bearing

With not more than 50 PSI (344,8 kPa) difference between each cylinder.

8–2 TIMING GEARS

8–2.1 Injector Pump

8–2.2 Crankshaft

8–5.1

8–7 DE–RATING FOR ALTITUDE

When engines are operated in high altitude areas, such engine should be de–rated. The following table is given as a general guide, which may be applied on a percentage basis, where specific figures for a particular engine rating are not available.

Any necessary adjustments in this respect to the fuel pump should be carrier out by the C.A.V. dealer for the territory concerned.

8–8 TORQUE SPECIFICATIONS

The following torque figures are with the components lightly oiled before assembly.

The tab and shim washers can be left out where used on earlier engines, but the capscrews must be tightened to the torque loading shown.

Nuts on the end of axles: tighten until there is resistance when turning axle by hand.

Nuts on steering centering spring: tighten until length of spring if 2.260 inches –2.340 inches (57,5–59,4 mm)

Standard Torque Specifications For Bolts

The above illustration shows the most common hex screw marking for each grade. A Grade 2 screw has no markings, a Grade 5 screw has three radial dashes 120 degrees apart, a Grade 8 screw has six radial dashes 60 degrees apart.

THREADGRADE–2GRADE–5GRADE–8 SIZEDRYLUBEDRYLUBEDRYLUBE

(108.5–135.6)(88.1–108.5)(196.6–244.0)(142.4–176.3)(264.4–325.4)(196.6–244.0)

3/4–Coarse130–16095–12021–260160–200300–380225–280 (176.3–216.9)(128.8–162.7)(284.7–352.5)(216.9–271.2)(406.8–515)(305.1–379.61)

3/4–Fine145–180115–140240–300180–220340–420255–320 (196.6–244.01)(155.9–189.8)(325.4–406.1)(244.0–298.3)(460.1–569)(345.1–433.9)

7/8–Coarse115–14090–110320–400240–300500–600370–460 (155.9–189.8)(122.0–149.1)(433.9–542)(325.4–406.8)(678–814)(502–624)

7/8–Fine125–15595–120350–440255–320560–660400–500 (169.5–210.2)(128.8–162.7)(474.5–598)(345.7–433.9)(759–895)(542–678)

1–Coarse180–200130–160480–580350–440800–900580–680 (244.1–298.3)(176.3–216.9)(651–786)(475–598)(1085–1220)(786–922)

1–Fine200–250140–175560–660400–490920–1020665–765 (271.2–338.9)(189.8–237.3)(759–895)(542–664)(1247–1383)(902–1037)

Decimal And Millimeter Equivalents

PD 1C Valve Guide Remove and Replacer

With this tool, all valve guides can be removed and replaced provided puller bars are available.

PD 1C–1 Puller Bars

Two bars are supplied for use with PD 1C to suit 0.3125 inch and 0.3750 inch I.D. valve guide bores.

PD 1C–2 Valve Guide Replacing Stop

When the valve guide is replaced using one of these stops, it will ensure that the guide protrudes the correct amount above the top face of the cylinder head.

PD 150 Cylinder Liner Remover and Replacer

PD 150–5 Adaptors for PD 150

316X Valve Seat Cutter Handle

This tool is required for the operation of all cutters and pilots.

316–10 Valve Seat Cutter Pilot

This pilot is suitable for all guides that have a nominal 0.3125 inch I.D. bore.

PD 317–22 Valve Seat Cutter Inlet

PD 317–G19 Glaze Breaker Exhaust

PD–317–G22 Glaze Breaker Inlet

Remarks: See PD 317–23

FC9900 Atomizer Tester

This is a portable tester fitted with a paper filter element.

335 Connecting Rod Alignment Jig

Enables a quick check to be made on the alignment of connecting rods – various adaptors are required as follows:

PD–336–102 Adaptor

This adaptor is fitted into the big end bore when checking alignment.

6118B Valve Spring Compressor

This valve spring compressor has been designed to remove valve springs without removing the cylinder head, providing the adaptors are available.

PD 6118–1 Valve Spring Compressor Adaptor

The adaptor is fitted to the rocker shaft securing studs.

& speed controlled by two steering levers & hand grip range selector

Lift, Tilt & Auxiliary functions controlled by separate foot pedals hand lever throttle & key type starter switch mechanical disc, hand operated lever