5004426 JOHNSON THROTTLE ARM ASSY.

9U7990 Counter Bore Tool Group. Consists: 1. 9U7985 Basic Counterbore Tool Group (metal box included but not shown) 4. 9U7986 Base and Micrometer Group (case included but not shown) (part of 9U7985 Basic Counterbore Tool Group)14. 9U7987 Master Gauge (part of 9U7985 Basic Counterbore Tool Group)2. 5P7983 Offset Washer (3 required)3. 0L1328 Bolt, 3/4-16 × 4" (3 required)5. 5P8248 Washer, 3/4" (3 required)6. 8T0207 Bolt, M16 × 2 × 100mm (3 required)7. 5P1656 Tool Remover Hook8. 5P1630 Drive Adapter9. 0S1569 Bolt, 5/8-11 × 4" (3 required)10. 5P8247 Washer, 5/8" (3 required)11. 1U7575 Allen Wrench, 1/8"12. 1U7576 Allen Wrench, 5/32"13. 1U7577 Allen Wrench, 3/16"15. 9U7984 Depth Set Spacer Optional Tool
9U7993 Gauge Assembly, Depth (case included but not shown) Cutter Plate and Cutter Bit (Typical Example) 9U7988 Riser Plate Group (case included but not shown)The 9U7988 Riser Plate Group is available for use on 3300 Series Engines, eliminating the need to remove adjacent cylinder liners.Cutter Plate, Cutter Bit, and Machining Dimensions for Cylinder Block
Preparation for Machining
Care and Maintenance of the Hydraulic-Feed Housing
The oil level should always be checked prior to initial use. If a low oil condition exists, tool chatter will occur. The oil level should also be checked periodically to prevent chatter (once a month is sufficient).Check Oil Level
Lay the feed unit on its side with the oil port 1 in the highest position. Support the feed unit so that it lays in the horizontal position. Remove the oil port plug. The feed unit is full when the oil is filled up into the threads. If the oil level is below the threads, then top off using only 30 weight non-detergent motor oil. Open feed valve and slowly rotate and push the mainshaft of the counterbore tool in and out. Top off the oil level any time the oil level drops below the threads. Continue this procedure until no more bubbles appear and oil level is maintained into the threaded area. Replace oil port plug.Cutter Plate Inspection
Always inspect the cutter plate for nicks, burrs or excessive wear (it should be smooth) before proceeding. Refer to the chart "Cutter Plate, Cutter Bit, and Machining Dimensions for Cylinder Block" for the correct cutter plate. Inspect and adjust the ball spring plunger screw (brass colored) which provides tension to the cutter bit. To adjust this screw to the proper tension, first install a cutter bit into the cutter slot. Tighten the tension screw completely. Then back the screw 1/4 of a turn. Cutter tension is now properly adjusted.Verifying the Micrometer Group
9U7986 Base and Micrometer Group (case included but not shown) Check micrometer group prior to setting the cutter. Clean all measuring surfaces before using micrometer, master gauge or cutter. Inspect cutter stop (B) and cutter tip for nicks, if damaged, replace.1. Install 9U7987 Master Gauge (A) in 9U7986 Micrometer Group with the side marked UP, on top as shown. Hold master gauge firmly against cutter stop (B) and surface (F) when checking master gauge or setting cutter. Turn micrometer thimble until spindle (E) fits snugly against the setting standard. The micrometer should read 5.000".2. When micrometer adjustment is required, loosen socket head screw (C) and move micrometer slightly away from cutter stop (B). Set micrometer to read 5.000".3. Slide micrometer to fit snugly against master gauge (A) and securely tighten socket head cap screw (C).4. Back off micrometer (D) and re-tighten to fit snugly against master gauge (A). Recheck the micrometer which should read 5.000". If it doesn't read 5.000" repeat steps 2 through 4.Verifying Master Gauge
1. Always check micrometer group first by referring to procedure "Verifying the Micrometer Group."2. Use a scrap engine block to perform this check.3. Measure bore in block, add +.040" to measured bore. This will be the test bore dimension. 4. Set cutter to test bore dimension.5. Bore hole and measure.6. Compare against set cutter dimension. ExampleIf measured bore is 6.291" it is oversize by 001". The master gauge would require .0005" material removal, lap to size by removing material from stem side of master gauge.If bore measures undersize, example 6.289" then master gauge should be replaced. Order 9U7987 MASTER GAUGE and follow instructions "Machining New Master Gauge to Size." Undersize bore cuts can be caused by damaged master gauge or worn bushings in machine.Machining New Master Gauge to Size
Use a scrap engine block to perform this test.1. Measure bore in block, add +.040" to measured bore. This will be the test bore dimension. 2. Set cutter, bore block and measure diameter.3. Verify cutter still measures original setting of 6.290".4. If the size of newly cut bore is different than the 6.290" cutter setting with the cutter bit in the micrometer group, then loosen micrometer holding screw and adjust micrometer to read measured bore size of newly cut hole.5. Tighten micrometer holding screw at this measurement.6. Place master gauge into micrometer group and turn micrometer thimble down until spindle touches the setting standard. New setting standards are .010" to .020" oversize.7. Read micrometer.8. Half the difference between the micrometer reading and 5.000" is the amount to grind or lap off the end of the master gauge to read 5.000" on the micrometer. ExampleNew setting master gauge reads 5.010". This is .010" oversize. Grind or lap .005" from the stem side of setting gauge.9. Carefully grind or lap master gauge. The micrometer should read 5.000". The micrometer and setting standard are now set correctly.Setting Cutter for Bore Diameter
1. Loosen the set screw in back end of cutter. Push spring loaded adjusting pin into body of cutter all the way. Tighten set screw.2. After verifying the micrometer group, set micrometer for .040" less than the bore diameter listed in the chart "Machining Dimensions for Cylinder Block." It has been determined through testing, that if two cuts are made to machine for an insert, the bore will be much more accurate and have a higher quality surface finish. 3. Place cutter in micrometer group and hold it firmly against the micrometer spindle (E) and surface (F).4. Loosen set screw (G)