Measure crankshaft and remount in bearings

AR03.20-G-4355DD

Measure crankshaft and remount in bearings

04.09.2019

Engine

900.91/92 in model 000.001

Engine

902.91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.90/93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

Shown on engine 904.9

1

Crankshaft

A

Main bearing journal Ø

E

Connecting rod journal width

2

Hardness tester

B

Fitted bearing journal width

F

Fillet radii of main and connecting rod journals

3

Outside micrometer

C

Main bearing journal width

G

Spherical shape of piston ring main and connecting rod journals

4

Crankshaft bearing cap

D

Connecting rod journal-Ø

H

Main bearing inner dia. when installed

5

Main bearing bolts

Shown on engine 904.9

1

Crankshaft

7

Mount dial indicator

8

Dial indicator holder

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Notes on hardness test

AH00.00-N-0012-01A

Notes on work safety regulations for vehicles with natural gas-powered engines

AH00.10-N-1000-04A



Remove

1

Remove crankshaft (1).

AR03.20-G-4351DD

2

Clean oil duct.

AR01.40-G-8501DD

 After bearing damage has occurred, remove any swarf that may be present.

3

Clean crankshaft (1).



Check

4

Check front crankshaft flange for wear.

If wear is detected,



Replace crankshaft (1).

5

Inspect main and connecting rod journals for damage and cracks.

If damage or cracks are present:



Replace crankshaft (1).

6

Check hardness of main and connecting rod journals of crankshaft (1) using a hardness tester (2).

AR03.20-G-4351-09DD

 Subject the main and connecting rod journals of crankshaft (1) to be checked to testing.
The hardness value must be at least two thirds of the circumference of the bearing journal.

Hardness of main bearing and connecting rod journals (Rockwell hardness)

*BE03.20-N-1013-02K

 Hardness tester

*000589202100

If the hardness value is not attained:



Replace crankshaft (1).



Measure

7

Measure smooth operation of crankshaft (1) using dial indicator (7) and dial indicator holder (8).

AR03.20-G-4351-08DD

 Place crankshaft (1) on external main bearing journals.

Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)

*BE03.20-N-1011-02K

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

If the values are outside of the tolerance,



Replace crankshaft (1).

8

Clean the bearing points on crankshaft (1) with a lint-free cleaning cloth.

9

Measure main bearing journal.

 Measure main bearing journal dia. (A) with outside micrometer (3) at two points (offset about 90°).

Permissible taper

*BE03.20-N-1009-02K

Main bearing journal width

*BE03.20-N-1003-02K

Fitted bearing journal width

*BE03.20-N-1002-02K

Main bearing journal Ø

*BE03.20-N-1001-02K

The measurement values lie outside the tolerance:



Machine crankshaft (1) to the next deviation or replace.

10

Measure connecting rod journal.

 Measure connecting rod journal dia. (A) with outside micrometer (3) at two points (offset by about 90°).

Connecting rod bearing journal Ø

*BE03.20-N-1004-02K

Connecting rod journal width

*BE03.20-N-1005-02K

Permissible taper

*BE03.20-N-1009-02K

Fillet radii

*BE03.20-N-1012-02K

Spherical shape of piston ring

*BE03.20-N-1014-02K

If the measurement values lie outside the tolerance:



Machine crankshaft (1) to the next deviation or replace.



Install

11

Mount crankshaft (1) radially.

AR03.20-G-4355-01DD

 Bolt, main bearing cap to crankcase

*BA01.40-N-1001-01M

Main bearing journal Ø

*BE03.20-N-1001-02K

Main bearing inner Ø

*BE03.20-N-1015-02K

 Dial gage

*001589532100

12

Install crankshaft (1).

AR03.20-G-4351DD

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1001-02K

Main bearing journal Ø

Standard

mm

85,990...86,010

85,990...86,010

Deviation –0.1

mm

85,890...85,910

85,890...85,910

Deviation –0.25

mm

85,740...85,760

85,740...85,760

Deviation –0.5

mm

85,490...85,510

85,490...85,510

Deviation –0.75

mm

85,240...85,260

85,240...85,260

Deviation –1.0

mm

84,990...85,010

84,990...85,010

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1001-02K

Main bearing journal Ø

Standard

mm

85,990...86,010

85,990...86,010

Deviation –0.1

mm

85,890...85,910

85,890...85,910

Deviation –0.25

mm

85,740...85,760

85,740...85,760

Deviation –0.5

mm

85,490...85,510

85,490...85,510

Deviation –0.75

mm

85,240...85,260

85,240...85,260

Deviation –1.0

mm

84,990...85,010

84,990...85,010

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1001-02K

Main bearing journal Ø

Standard

mm

85,990...86,010

Deviation –0.1

mm

85,890...85,910

Deviation –0.25

mm

85,740...85,760

Deviation –0.5

mm

85,490...85,510

Deviation –0.75

mm

85,240...85,260

Deviation –1.0

mm

84,990...85,010

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1002-02K

Fitted bearing journal width

Standard Ø

mm

85,990...86,010

85,990...86,010

Standard width

mm

31,000...31,062

31,000...31,062

Ø deviation -0.1

mm

85,890...85,910

85,890...85,910

Standard width

mm

31,000...31,062

31,000...31,062

Ø deviation -0.1

mm

85,890...85,910

85,890...85,910

Width deviation 0.3

mm

31,300...31,362

31,300...31,362

Ø deviation -0.25

mm

85,740...85,760

85,740...85,760

Width deviation 0.3

mm

31,300...31,362

31,300...31,362

Ø deviation -0.5

mm

85,490...85,510

85,490...85,510

Width deviation 0.5

mm

31,500...31,562

31,500...31,562

Ø deviation -0.75

mm

85,240...85,260

85,240...85,260

Width deviation 0.5

mm

31,500...31,562

31,500...31,562

Ø deviation -1.0

mm

84,990...85,010

84,990...85,010

Width deviation 0.5

mm

31,500...31,562

31,500...31,562

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1002-02K

Fitted bearing journal width

Standard Ø

mm

85,990...86,010

85,990...86,010

Standard width

mm

31,000...31,062

31,000...31,062

Ø deviation -0.1

mm

85,890...85,910

85,890...85,910

Standard width

mm

31,000...31,062

31,000...31,062

Ø deviation -0.1

mm

85,890...85,910

85,890...85,910

Width deviation 0.3

mm

31,300...31,362

31,300...31,362

Ø deviation -0.25

mm

85,740...85,760

85,740...85,760

Width deviation 0.3

mm

31,300...31,362

31,300...31,362

Ø deviation -0.5

mm

85,490...85,510

85,490...85,510

Width deviation 0.5

mm

31,500...31,562

31,500...31,562

Ø deviation -0.75

mm

85,240...85,260

85,240...85,260

Width deviation 0.5

mm

31,500...31,562

31,500...31,562

Ø deviation -1.0

mm

84,990...85,010

84,990...85,010

Width deviation 0.5

mm

31,500...31,562

31,500...31,562

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1002-02K

Fitted bearing journal width

Standard Ø

mm

85,990...86,010

Standard width

mm

31,000...31,062

Ø deviation -0.1

mm

85,890...85,910

Standard width

mm

31,000...31,062

Ø deviation -0.1

mm

85,890...85,910

Width deviation 0.3

mm

31,300...31,362

Ø deviation -0.25

mm

85,740...85,760

Width deviation 0.3

mm

31,300...31,362

Ø deviation -0.5

mm

85,490...85,510

Width deviation 0.5

mm

31,500...31,562

Ø deviation -0.75

mm

85,240...85,260

Width deviation 0.5

mm

31,500...31,562

Ø deviation -1.0

mm

84,990...85,010

Width deviation 0.5

mm

31,500...31,562

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1003-02K

Main bearing journal width

mm

31,0...31,2

31,0...31,2

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1003-02K

Main bearing journal width

mm

31,0...31,2

31,0...31,2

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1003-02K

Main bearing journal width

mm

31,0...31,2

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1004-02K

Connecting rod bearing journal Ø

Standard

mm

69,995...70,015

69,995...70,015

Deviation –0.1

mm

69,895...69,915

69,895...69,915

Deviation –0.25

mm

69,745...69,765

69,745...69,765

Deviation –0.5

mm

69,495...69,515

69,495...69,515

Deviation –0.75

mm

69,245...69,265

69,245...69,265

Deviation –1.0

mm

68,995...69,015

68,995...69,015

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1004-02K

Connecting rod bearing journal Ø

Standard

mm

69,995...70,015

69,995...70,015

Deviation –0.1

mm

69,895...69,915

69,895...69,915

Deviation –0.25

mm

69,745...69,765

69,745...69,765

Deviation –0.5

mm

69,495...69,515

69,495...69,515

Deviation –0.75

mm

69,245...69,265

69,245...69,265

Deviation –1.0

mm

68,995...69,015

68,995...69,015

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1004-02K

Connecting rod bearing journal Ø

Standard

mm

69,995...70,015

Deviation –0.1

mm

69,895...69,915

Deviation –0.25

mm

69,745...69,765

Deviation –0.5

mm

69,495...69,515

Deviation –0.75

mm

69,245...69,265

Deviation –1.0

mm

68,995...69,015

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1005-02K

Connecting rod journal width

mm

34,0...34,2

34,0...34,2

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1005-02K

Connecting rod journal width

mm

34,0...34,2

34,0...34,2

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1005-02K

Connecting rod journal width

mm

34,0...34,2

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1009-02K

Permissible taper

Main bearing journals

mm

0,005

0,005

Connecting rod journals

mm

0,005

0,005

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1009-02K

Permissible taper

Main bearing journals

mm

0,005

0,005

Connecting rod journals

mm

0,005

0,005

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1009-02K

Permissible taper

Main bearing journals

mm

0,005

Connecting rod journals

mm

0,005

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1011-02K

Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)

mm

0,11

0,15

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1011-02K

Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)

mm

0,15

0,11

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1011-02K

Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)

mm

0,15

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1012-02K

Fillet radii

Main bearing journals

mm

2,5...3,0

2,5...3,0

Connecting rod journals

mm

2,5...3,0

2,5...3,0

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1012-02K

Fillet radii

Main bearing journals

mm

2,5...3,0

2,5...3,0

Connecting rod journals

mm

2,5...3,0

2,5...3,0

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1012-02K

Fillet radii

Main bearing journals

mm

2,5...3,0

Connecting rod journals

mm

2,5...3,0

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1013-02K

Hardness of main bearing and connecting rod journals (Rockwell hardness)

HRC

52

52

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1013-02K

Hardness of main bearing and connecting rod journals (Rockwell hardness)

HRC

52

52

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1013-02K

Hardness of main bearing and connecting rod journals (Rockwell hardness)

HRC

52

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1014-02K

Spherical shape of piston ring

Main bearing journals

mm

0,000...0,004

0,000...0,004

Connecting rod journals

mm

0,000...0,004

0,000...0,004

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1014-02K

Spherical shape of piston ring

Main bearing journals

mm

0,000...0,004

0,000...0,004

Connecting rod journals

mm

0,000...0,004

0,000...0,004

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1014-02K

Spherical shape of piston ring

Main bearing journals

mm

0,000...0,004

Connecting rod journals

mm

0,000...0,004

Check values of crankshaft

Number

Designation

ENGINE 900.9

ENGINE 902.9, 906.9 except 906.901/902

BE03.20-N-1015-02K

Main bearing inner Ø

Standard

mm

86,066...86,108

86,066...86,108

Deviation 0.1

mm

85,966...86,008

85,966...86,008

Deviation 0.25

mm

85,816...85,858

85,816...85,858

Deviation 0.5

mm

85,566...85,608

85,566...85,608

Deviation 0.75

mm

85,316...85,358

85,316...85,358

Deviation 1.0

mm

85,066...85,108

85,066...85,108

Check values of crankshaft

Number

Designation

ENGINE 906.901/902

ENGINE 904.9

BE03.20-N-1015-02K

Main bearing inner Ø

Standard

mm

86,066...86,108

86,066...86,108

Deviation 0.1

mm

85,966...86,008

85,966...86,008

Deviation 0.25

mm

85,816...85,858

85,816...85,858

Deviation 0.5

mm

85,566...85,608

85,566...85,608

Deviation 0.75

mm

85,316...85,358

85,316...85,358

Deviation 1.0

mm

85,066...85,108

85,066...85,108

Check values of crankshaft

Number

Designation

Engine 924.9, 925.9, 926.9 in model 000.001

BE03.20-N-1015-02K

Main bearing inner Ø

Standard

mm

86,066...86,108

Deviation 0.1

mm

85,966...86,008

Deviation 0.25

mm

85,816...85,858

Deviation 0.5

mm

85,566...85,608

Deviation 0.75

mm

85,316...85,358

Deviation 1.0

mm

85,066...85,108

 Crankcase, timing case cover, end cover

Number

Designation

Engine 900.9, 902.9, 904.9, 906.9 in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA01.40-N-1001-01M

Bolt, main bearing cap to crankcase

Stage 1

Nm

30

30

Stage 2

Nm

80

80

Stage 3

Nm

155

155

Stage 4

°

90

90