Machine crankcase

AR01.40-W-9203J

Machine crankcase

25.06.2019

Engine

900.9 in model 375.1, 970, 972, 975, 976

Engine

902.9 in model 375.1, 970, 972, 974, 975, 976

Engine

902.9 in model 375.3, 950, 952, 953, 954

Engine

902.9 in model 957

except code MS8 (Natural gas engine)

Engine

924.9 in model 970, 972, 974, 975, 976

Engine

925.9 in model 970, 972, 974

Engine

926.9 in model 950, 952, 953, 954, 957

Shown on engine 902.9

1

Crankcase

A

Crankcase height

B

Cylinder barrel inside diameter



Remove

1

Remove cylinder head

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR01.30-W-5800J

Model 957

AR01.30-W-5800JB

2

Remove pistons

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR03.10-W-7021J

3

Remove crankshaft

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR03.20-W-4351J

4

Remove camshaft

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR05.20-W-6292J

5

Remove engine control/PLN unit pumps

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR07.15-W-8950J

Model 957

AR07.15-W-8950JB

6

Remove oil filter housing

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR18.20-W-3471J

Model 957

AR18.20-W-3471JB

7

Remove heat exchanger

ENGINE 900.9, 924.9

AR18.30-W-6840JA

Engine 902.9, 925.9, 926.9 except in model 957

AR18.30-W-6840J

Engine 902.9, 926.9 in model 957

AR18.30-W-6840JB

8

Remove coolant pump

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR20.10-W-1271J

Model 957

AR20.10-W-1271D

9

Remove oil spray nozzles

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR18.00-W-4000J

10

Remove remaining detachable parts on crankcase (1)



Check

11

Check cylinder barrel for wear

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR01.40-W-9202J

Notes for evaluation of a cylinder barrel

AH01.40-N-0001-03A

12

Check crankcase (1) for damage and check its flatness using a straightedge

Crankcase flatness of separating surface

*BE01.40-N-1013-02B

Edit

13

Determine machining phase of cylinder crankcase height (A) and cylinder barrel inside diameter (B)


When face machining the cylinder crankcase height (A) and machining the cylinder barrel inside diameter (B), the same dimension stages must be applied,
as no other piston assignments are possible..

 Only machine crankcase (1) flat if an impermissible variation in flatness is measured in the longitudinal direction, or if there are damaged areas.

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

*BE01.40-N-1021-02B

14

Align crankcase (1) on machine tool and clamp in place

 Pay attention to manufacturer's operating instructions.

15

Drill out cylinder barrel-inside diameter (B)


The machining sequence must be observed.
This will otherwise lead to a high thermal load of the crankcase (1).

 All cylinder barrel inside diameter (B) must be drilled to the same tolerance level.

 For 4-cylinder engines: cylinders 2-4-1-3
For 6-cylinder engines: cylinders 1-4-5-2-3-6

 Pay attention to manufacturer's operating instructions.

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

*BE01.40-N-1021-02B

16

Machine crankcase housing height (A)


The surface quality must be maintained.
Thus the sealing is maintained.

 The crankcase housing height (A) must have the same tolerance level as the cylinder barrel inside diameter (B).

Peak-to-valley height (Rz) of crankcase contact surface

*BE01.40-N-1011-02B

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

*BE01.40-N-1021-02B

17

Deburr crankcase (1) on the chamfer

18

Hone cylinder barrel-inside diameter (B) to the desired final dimension

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

*BE01.40-N-1021-02B

Peak-to-valley height (R3z) cylinder barrel

*BE01.40-N-1004-02B

19

Clean crankcase (1)

 Check bores and passages for unrestricted flow.



Measure

20

Measure and note cylinder barrel inside diameter (B)

AR01.40-W-9202J

21

Assign pistons to the cylinder barrel inside diameter (B)

AR03.10-W-7021-03R

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

*BE01.40-N-1021-02B

Piston dia. and piston compression height

*BE03.10-N-1006-02B

22

Mark crankcase (1) after machining

AR01.40-W-9273-01J

 The marking areas must be corrected after every machining of the crankcase (1).

Cylinder bore inner diameter

*BE01.40-N-1001-02B

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

*BE01.40-N-1021-02B



Install

23

Mount detachable parts on crankcase (1)

24

Install oil spray nozzles

AR18.00-W-4000J

25

Install coolant pump

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR20.10-W-1271J

Model 957

AR20.10-W-1271D

26

Install heat exchanger

Engine 900.9, 924.9

AR18.30-W-6840JA

Engine 902.9, 925.9, 926.9 except in model 957

AR18.30-W-6840J

Engine 902.9, 926.9 in model 957

AR18.30-W-6840JB

27

Install oil filter housing

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR18.20-W-3471J

Model 957

AR18.20-W-3471JB

28

Install camshaft

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR05.20-W-6292J

29

Install engine control/PLN unit pump

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR07.15-W-8950J

Model 957

AR07.15-W-8950JB

30

Install crankshaft

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR03.20-W-4351J

31

Install pistons

Engine 900.9 in model 375.1, 970, 972, 975, 976
Engine 902.9 in model 375.1, 970, 972, 974, 975, 976
Engine 902.9 in model 375.3, 950, 952, 953, 954
Engine 902.9 in model 957
except code MS8 (Natural gas engine)
Engine 924.9 in model 970, 972, 974, 975, 976
Engine 925.9 in model 970, 972, 974
Engine 926.9 in model 950, 952, 953, 954, 957

AR03.10-W-7021J

32

Install cylinder head

MODELS 375, 950, 952, 953, 954, 970, 972, 974, 975, 976

AR01.30-W-5800J

Model 957

AR01.30-W-5800JB

Check values of crankcase

Number

Designation

Engine 902.9 with code MS8, engine 906.9 with code MS8

Engine 924.9, 925.9, 926.9 without code MS4 or MS5

BE01.40-N-1001-02B

Cylinder bore inner diameter

Code letter A

mm

105,985...105,991

105,985...105,991

Code letter B

mm

105,992...106,008

105,992...106,008

Code letter C

mm

106,009...106,015

106,009...106,015

Check values of crankcase

Number

Designation

Engine 924.9, 925.9, 926.9 with code MS4 or MS5

Engine 900.9 , engine 902.9 without code MS8

BE01.40-N-1001-02B

Cylinder bore inner diameter

Code letter A

mm

105,985...105,991

101,985...101,991

Code letter B

mm

105,992...106,008

101,992...102,008

Code letter C

mm

106,009...106,015

102,009...102,015

Check values of crankcase

Number

Designation

Engine 902.9 with code MS8, engine 906.9 with code MS8

Engine 924.9, 925.9, 926.9 without code MS4 or MS5

BE01.40-N-1004-02B

Peak-to-valley height (R3z) cylinder barrel

μm

2,0...4,5

2,0...4,5

Check values of crankcase

Number

Designation

Engine 924.9, 925.9, 926.9 with code MS4 or MS5

Engine 900.9 , engine 902.9 without code MS8

BE01.40-N-1004-02B

Peak-to-valley height (R3z) cylinder barrel

μm

2,0...4,5

2,0...4,5

Check values of crankcase

Number

Designation

Engine 902.9 with code MS8, engine 906.9 with code MS8

Engine 924.9, 925.9, 926.9 without code MS4 or MS5

BE01.40-N-1011-02B

Peak-to-valley height (Rz) of crankcase contact surface

μm

4...16

4...16

Check values of crankcase

Number

Designation

Engine 924.9, 925.9, 926.9 with code MS4 or MS5

Engine 900.9 , engine 902.9 without code MS8

BE01.40-N-1011-02B

Peak-to-valley height (Rz) of crankcase contact surface

μm

4...16

4...16

Check values of crankcase

Number

Designation

Engine 902.9 with code MS8, engine 906.9 with code MS8

Engine 924.9, 925.9, 926.9 without code MS4 or MS5

BE01.40-N-1013-02B

Crankcase flatness of separating surface

over the entire length

mm

0,030

0,030

Over a length of 150 mm in longitudinal or Transverse direction

mm

0,015

0,015

Check values of crankcase

Number

Designation

Engine 924.9, 925.9, 926.9 with code MS4 or MS5

Engine 900.9 , engine 902.9 without code MS8

BE01.40-N-1013-02B

Crankcase flatness of separating surface

over the entire length

mm

0,030

0,030

Over a length of 150 mm in longitudinal or Transverse direction

mm

0,015

0,015

Check values of crankcase

Number

Designation

Engine 902.9 with code MS8, engine 906.9 with code MS8

Engine 924.9, 925.9, 926.9 without code MS4 or MS5

BE01.40-N-1021-02B

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

Height standard 0

mm

298,35...298,50

298,33...298,40

Cylinder internal bore Ø code letter A

mm

–

105,985...105,991

Code letter B

mm

–

105,992...106,008

Code letter C

mm

–

106,009...106,015

Height deviation -0.3

mm

298,05...298,20

298,03...298,10

Cylinder internal bore Ø code letter A

mm

–

106,285...106,291

Code letter B

mm

–

106,292...106,308

Code letter C

mm

–

106,309...106,315

Height deviation -0.6

mm

297,75...297,90

297,73...297,80

Cylinder internal bore Ø code letter A

mm

–

105,585...106,591

Code letter B

mm

–

105,992...106,608

Code letter C

mm

–

106,609...106,615

Height deviation -0.9

mm

–

297,43...297,50

Cylinder internal bore Ø code letter A

mm

–

106,885...106,891

Code letter B

mm

–

106,892...106,908

Code letter C

mm

–

106,909...106,915

Check values of crankcase

Number

Designation

Engine 924.9, 925.9, 926.9 with code MS4 or MS5

Engine 900.9 , engine 902.9 without code MS8

BE01.40-N-1021-02B

Cylinder crankcase height (A), measured from the main bearing shell seat to the cylinder head contact surface and cylinder bore internal Ø

Height standard 0

mm

298,33...298,40

298,33...298,40

Cylinder internal bore Ø code letter A

mm

105,985...105,991

101,985...101,991

Code letter B

mm

105,992...106,008

101,992...102,008

Code letter C

mm

106,009...106,015

102,009...102,015

Height deviation -0.3

mm

298,03...298,10

298,03...298,10

Cylinder internal bore Ø code letter A

mm

106,285...106,291

102,285...102,291

Code letter B

mm

106,292...106,308

102,292...102,308

Code letter C

mm

106,309...106,315

102,309...102,315

Height deviation -0.6

mm

297,73...297,80

297,73...297,80

Cylinder internal bore Ø code letter A

mm

105,585...106,591

102,585...102,591

Code letter B

mm

105,992...106,608

102,592...102,608

Code letter C

mm

106,609...106,615

102,609...102,615

Height deviation -0.9

mm

297,43...297,50

297,43...297,50

Cylinder internal bore Ø code letter A

mm

106,885...106,891

102,885...102,891

Code letter B

mm

106,892...106,908

102,892...102,908

Code letter C

mm

106,909...106,915

102,909...102,915

Test specifications for pistons

Number

Designation

Engine 902.9 with code MS8, engine 906.9 with code MS8

Engine 924.9, 925.9, 926.9 without code MS4 or MS5

BE03.10-N-1006-02B

Piston dia. and piston compression height

Standard-Ø 0 compression height

BA

mm

–

105,761...105,770

BC

mm

–

105,770...105,779

0

mm

–

61,36...61,40

Deviation Ø 0,3 compression height

BA

mm

–

106,061...106,070

BC

mm

–

106,070...106,079

–0,3

mm

–

61,06...61,10

Deviation-Ø 0,6Ø 102,6 compression height

BA

mm

–

106,361...106,370

BC

mm

–

106,370...106,379

0.6

mm

–

60,76...60,80

Deviation-Ø 0.9 Ø 102.9 compression height

BA

mm

–

106,661...106,670

BC

mm

–

106,670...106,679

–0,9

mm

–

60,46...60,50

Test specifications for pistons

Number

Designation

Engine 924.9, 925.9, 926.9 with code MS4 or MS5

Engine 900.9 , engine 902.9 without code MS8

BE03.10-N-1006-02B

Piston dia. and piston compression height

Standard-Ø 0 compression height

BA

mm

105,761...105,770

101,781...101,790

BC

mm

105,770...105,779

101,790...101.799

0

mm

61,36...61,40

64,36...64,40

Deviation Ø 0,3 compression height

BA

mm

106,061...106,070

102,081...102,090

BC

mm

106,070...106,079

102,090...102,099

–0,3

mm

61,06...61,10

64,06...64,10

Deviation-Ø 0,6Ø 102,6 compression height

BA

mm

106,361...106,370

102,381...102,390

BC

mm

106,370...106,379

102,390...102,399

0.6

mm

60,76...60,80

63,76...63,80

Deviation-Ø 0.9 Ø 102.9 compression height

BA

mm

106,661...106,670

102,681...102,690

BC

mm

106,670...106,679

102,690...102,699

–0,9

mm

60,46...60,50

63,46...63,50