Measure crankshaft and remount in bearings

AR03.20-P-4355AW

Measure crankshaft and remount in bearings

04.02.2019

Engine

601, 602 (except 602.98), 603

601DShown on engine 601: Oil grooves (arrow) in thrust plates (22) and (23) must point towards thrust collars of crankshaft.

A

Cylinder crankcase

B

Bearing cap

20

Crankshaft

21

Main bearing in bearing cap

22

Thrust plates (axial bearings) in bearing caps

23

Thrust plates (axial bearing) in cylinder crankcase engine 601 3rd main bearing = thrust bearing engine 602 4th main bearing = thrust bearing engine 603.5 main bearing = thrust bearing

24

Main bearing in crankcase



Remove

1

Remove crankshaft

Take into account the fit and bearing diagram

Bearing diagram for crankshaft

AH03.20-N-4351-01B

 Installation: Check length of crankshaft bearing cap bolt, replace if necessary (version 2)

 Bolt for crankshaft bearing cap

*BA03.20-P-1001-01A

 Bolt for crankshaft bearing

*BA03.20-P-1002-01A

2

Clean engine parts

If bearing damage has occurred, possibly present chips must be removed from connecting rod bores as well as crankshaft and cylinder crankcase oil ducts



Clean, seal main oil duct



Check

3

Check connecting rod, repair if necessary

AR03.10-P-6111AW


After bearing damage has occurred:
Connecting rods that overheated due to bearing damage (bluish coloration) must be replaced.
Connecting-rod shank may not have any transverse score marks and notches.

4

Check, repair crankshaft


After bearing damage has occurred:
Visual inspection! If damaged

5

Mount crankshaft radially in bearings

AR03.20-P-4355-01AW

Main bearing play

*BE03.20-P-1001-04C

Connecting rod bearing play

*BE03.20-P-1002-04C

Engine 601, 602.91/96, 603.91/96/97Crankshaft bearing

*BE01.40-P-1001-02D

Main bearing shells standard dimension for crankcase and bearing cap Ø 58.00 mm

*BE03.20-P-1001-03B

Engine 601, 602 (except 602.98), 603Crankshaft journal-Ø

*BE03.20-P-1001-02C

Engine 601, 602 (except 602.98), 603Connecting rod journal-Ø

*BE03.20-P-1002-02C

 Bolt for crankshaft bearing cap

*BA03.20-P-1001-01A

 Engine 601, 602 (except 602.98), 603Connecting rod screw (stretch shank)

*BA03.10-P-1001-01C

 Engine 601, 602 (except 602.98), 603Connecting rod bolt (stretch bolt)

*BA03.10-P-1002-01C

 Dial gage

*001589322100

A radial mounting for the main bearings is possible for standard dimension crankshafts by assigning the color-coded bearing shells, see



Assign crankshaft bearing shells

AR03.20-P-4360-01HA

6

Mount crankshaft axially

AR03.20-P-4355-02AW

Main bearing play

*BE03.20-P-1001-04C

Engine 601, 602 (except 602.98), 603Fit bearing journal width

*BE03.20-P-1003-02C

 Engine 601, 602 (except 602.98), 603Bolt for crankshaft bearing cap

*BA03.20-P-1001-01A

 Dial gage

*001589322100

 Dial indicator holder

*363589022100

7

Install in the reverse order

Check values for cylinder crankcase

Number

Designation

Engine 601, 602.91/96, 603.91/96

Engine 603.97

BE01.40-P-1001-02D

Crankshaft bearing

Basic bore diameter

mm

62,500...62,519

62,500...62,519

Basic bore width at fitted bearing

mm

19,979...20,000

19,979...20,000

Permissible out-of-roundness and taper of basic bore

mm

0,02

0,02

Check values of crankshaft

Number

Designation

ENGINE 601 up to 06/84

ENGINE 601 as of 07/84, 602 except 602.98, 603

BE03.20-P-1001-02C

Crankshaft journal-Ø

Standard size

mm

57,940...57,965

57,940...57,965

Repair stage 1

mm

57,700...57,715

57,700...57,715

Repair stage 2

mm

57,450...57,465

57,450...57,465

Repair stage 3

mm

57,200...57,215

57,200...57,215

Repair stage 4

mm

56,950...56,965

56,950...56,965

Check values for crankshaft main bearing shells

Number

Designation

ENGINE 601, 602 except 602.982, 603

BE03.20-P-1001-03B

Main bearing shells standard dimension for crankcase and bearing cap Ø 58.00 mm

Replacement part additional number (color coding blue)

52

Bearing shell thickness

mm

2,255–2,260

Test specifications for crankshaft bearing clearance

Number

Designation

ENGINE 601, 602 except 602.982, 603

BE03.20-P-1001-04C

Main bearing play

Radial measurement when new

mm

0,03–0,05

Radial wear limit

mm

0,08

Axial measurement when new

mm

0,10–0,25

Axial wear limit

mm

0,3

Check values of crankshaft

Number

Designation

ENGINE 601 up to 06/84

ENGINE 601 as of 07/84, 602 except 602.98, 603

BE03.20-P-1002-02C

Connecting rod journal-Ø

Standard size

mm

47,940...47,965

47,940...47,965

Repair stage 1

mm

47,700...47,715

47,700...47,715

Repair stage 2

mm

47,450...47,465

47,450...47,465

Repair stage 3

mm

47,200...47,215

47,200...47,215

Repair stage 4

mm

46,950...46,964

46,950...46,964

Test specifications for crankshaft bearing clearance

Number

Designation

ENGINE 601, 602 except 602.982, 603

BE03.20-P-1002-04C

Connecting rod bearing play

Radial measurement when new

mm

0,020–0,065

Check values of crankshaft

Number

Designation

ENGINE 601 up to 06/84

ENGINE 601 as of 07/84, 602 except 602.98, 603

BE03.20-P-1003-02C

Fit bearing journal width

Standard size

mm

26,500...26,520

24,500...24,533

–

mm

26,600...26,620

24,600...24,633

Repair stage

mm

26,700...26,720

24,700...24,733

–

mm

26,900...26,920

24,900...24,933

–

mm

27,000...27,020

25,000...25,033

 Connecting rod

Number

Designation

ENGINE 601, ENGINE 602.000/912/962, ENGINE 602.93/94, ENGINE 603.91/931/96/971/972 up to 30.11.90, ENGINE 603.970 up to 31.08.90

ENGINE 601, ENGINE 602.000/912/962, ENGINE 602.93/94, ENGINE 603.91/96/971 as of 01.12.90 up to 31.10.92, ENGINE 603.970 as of 01.09.90 up to 31.10.92

BA03.10-P-1001-01C

Connecting rod screw (stretch shank)

Stage 1

New

Nm

–

45

Used

Nm

–

40

Stage 2

°

–

90

Picture

-

AR03.10-P-6111-01AW

 Connecting rod

Number

Designation

ENGINE 601, ENGINE 602.000/912/962, ENGINE 602.93/94, ENGINE 603 as of 01.11.92

BA03.10-P-1001-01C

Connecting rod screw (stretch shank)

Stage 1

New

Nm

40

Used

Nm

–

Stage 2

°

90

Picture

AR03.10-P-6111-01AW

 Connecting rod

Number

Designation

ENGINE 601, ENGINE 602.000/912/962, ENGINE 602.93/94, ENGINE 603.91/931/96/971/972 up to 30.11.90, ENGINE 603.970 up to 31.08.90

ENGINE 601, ENGINE 602.000/912/962, ENGINE 602.93/94, ENGINE 603.91/96/971 as of 01.12.90 up to 31.10.92, ENGINE 603.970 as of 01.09.90 up to 31.10.92

BA03.10-P-1002-01C

Connecting rod bolt (stretch bolt)

Stage 1

Nm

30

–

Stage 2

°

90

–

Picture

AR03.10-P-6111-01AW

-

 Connecting rod

Number

Designation

ENGINE 601, ENGINE 602.000/912/962, ENGINE 602.93/94, ENGINE 603 as of 01.11.92

BA03.10-P-1002-01C

Connecting rod bolt (stretch bolt)

Stage 1

Nm

–

Stage 2

°

–

Picture

-

 Crankshaft

Number

Designation

Engine 601, 602 (except 602.98), 603

BA03.20-P-1001-01A

Bolt for crankshaft bearing cap

M11

Stage 1

Nm

55

Stage 2

°

90

 Crankshaft

Number

Designation

Engine 601, 602 (except 602.98), 603

BA03.20-P-1002-01A

Bolt for crankshaft bearing

M12

Nm

90