1.

Instructions for Measuring Engine Runouts

Engine flywheel housing (face/radial)
Engine flywheel (face/radial)
2. Instructions for Measuring Engine crankshaft endplay
3. Instructions for Shimming Alternator Driveplates
4. Instructions for Measuring Alternator Runouts
Shaft
Angular

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 Engine Flywheel Housing Face Runout-Measurement
SAE 00
Flywheel
Flywheel Housing Face Runout Housing
Cummins: 0.012” TIR
Detroit: 0.019” TIR
SAE J617: 0.019” TIR (Kato’s Limit) Flywheel

Dial
Indicator

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 Engine Flywheel Housing Radial Runout-Measurement
SAE 00
Flywheel
Flywheel Housing Radial Runout Housing

Cummins: 0.012” TIR

Detroit: 0.019” TIR
Flywheel
SAE J617: 0.019” TIR (Kato’s Limit)

Dial
Indicator

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 Engine Flywheel Face Runout-Measurement

Flywheel Face Runout Flywheel

Housing
Cummins: 0.012” TIR
(Kato’s Limit, measured near the bolt circle)
Flywheel
Detroit: 0.008” TIR
SAE J620: 0.0005 times measured diameter
Dial
Note: This runout measurement depends on
Indicator
the radial location of the dial-indicator.

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 Engine Flywheel Radial Runout-Measurement

Flywheel Radial Runout Flywheel

Housing
Cummins: 0.005” TIR
Detroit: 0.008” TIR
SAE J620: 0.005” TIR (Kato’s Limit)
Flywheel

Dial
Indicator

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 Engine Crankshaft Endplay-Measurement

Flywheel
Allowable Crankshaft Endplay Housing

Cummins: 0.005” – 0.020”

Flywheel
Detroit: 0.008” - 0.023”
Dial
Indicator

Crankshaft

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 Engine Flywheel Nominal Axial Position-Measurement
0
Measurement: - +
Determine the nominal axial position of the
flywheel. Take 4 averaged readings, 90 degrees
apart measuring from the housing face to the
Flywheel
flywheel face.
Housing
All dimensions are measured relative to the Face
flywheel housing face. Positive (+) values when the
flywheel face is inside the housing face and
Negative (-) values when the flywheel face is
outside the housing face.
Flywheel
1. Push/force crankshaft towards the engine. Face
Record this +/- value as the FPI (Flywheel Position
Inward).
2. Pull/force crankshaft away from engine.
Record this +/- value as the FPO (Flywheel
Position Outward).

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 Alternator Driveplate Axial Position-Measurement
Axial Position of Alternator Driveplates 0
Measurement: Frame + -
Determine the axial position of the driveplate
face. With rotor centered (lifted) in stator, take 4
averaged readings, 90 degrees apart
measuring from the housing face to the
driveplate face. Alternator
Housing
All dimensions are measured relative to the
Face
alternator housing face. Positive (+) values
when the driveplate face is inside the housing
face and Negative (-) values when the
driveplate face is outside the housing face.
Driveplate
Record this +/-value as the DPP (Driveplate
Face
Position).
Note:
1. Kato Engineering assemblies the driveplates
with a zero offset +/-0.005” relative to the
alternator housing face.
2. The axial endplay is zero since the bearing is
secured in the bearing housing.
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 Alternator Driveplate Shimming

Driveplates Shimming
Determine the correct amount of driveplate shims.
Calculations:
1. [(FPO) + (FPI)] x 0.5 = FPN
FPN: Flywheel Position Nominal
If FPN is positive, the flywheel’s nominal position is
inside the flywheel housing face. Driveplate
If FPN is negative, the flywheel’s nominal position is Shims
outside the flywheel housing face.
2. (DPP) + (FPN) = THK
THK: thickness of shims to be removed or added
If THK is positive, this is the amount of shims to be
added.
If THK is negative, this is the amount of shims to be
removed.
When THK is between -0.010” and +0.010, the
correct amount of shims are installed.
3. Torque driveplate bolts to 280 ft-lb

Note:
Kato Engineering supplies additional shims that
are shipped with the alternator.
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 Alternator Shaft Runout-Measurement

Alternator Shaft Runout

Dial
Kato Eng Spec: 0.003” TIR Indicator

1.Remove all rust-preventive material on shaft

before measuring TIR.
2. Set the base of the dial-indicator on alternator
frame, and the probe of the indicator on the
shaft, near the coupling hub.
(Do not measure on hub OD)
3.Rotate rotor/engine 360 degrees and record
the high and low readings and angular positions

Coupling Hub
In order to achieve 0.003” TIR or less:
a. Loosen flywheel bolts with the high reading
up, allow rotor to drop
b. Remove flywheel bolts, rotate the engine 90 Alternator Shaft
degrees
c. Combination of the ‘a’ and ‘b’ listed above.
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 Alternator Angular Runout-Measurement

Alternator Angular Runout

Kato Eng Spec: 0.015” TIR

Dial
1.Set the base of the dial-indicator on the Indicator
alternator shaft, and the probe of the gage Flywheel
on the back of a flywheel bolt.
2.Rotate rotor/engine 360 degrees and
record the high/low readings. The difference
is the ‘Total Indicated Runout’.
Driveplate/flywheel
bolt
NOTE:
0.015” or less is desirable, please consult
Kato Engineering if this measurement
exceeds 0.015”.

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 Engine & Alternator Mating Diameters
(reference)

Flywheel Housing Recess Diameter Flywheel Recess Diameter

Cummins: 31.010+/-0.010 Cummins: 26.500+0.002/-0.000
Detroit: Detroit:
SAE J617: 31.000+0.010/-0.000 SAE J620: 26.500+0.005/-0.000

Alternator Adapter Pilot Diameter Flex-Driveplates

Kato Engineering: 30.999/30.995” Kato Engineering: 26.497+/-0.001

SAEJ1033 Procedure for Measuring Bore Eccentricity and Face

Deviation for Flywheels and Flywheel Housings
Applicable for the Cummins QSK60 and Detroit MTU 16V4000 engines

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