Measure crankshaft and remount in bearings

AR03.20-W-4355B

Measure crankshaft and remount in bearings

12.12.08



Checking

1

Remove crankshaft (1)

AR03.20-W-4351A

2

Clean engine parts

 Any chips which are present must be taken away after bearing damage has occurred:



Clean main oil gallery.

AR01.40-W-8501A

3

Clean crankshaft (1)

4

Check front crankshaft flange for wear

 Machine crankshaft (1) if these is wear.

5

Inspect main and connecting rod bearing journals for damage and cracks

 If damage or cracks are present:



Replace crankshaft (1).



Measure

6

Measure hardness of main bearing shaft and connecting rod bearing shaft journals of the crankshaft (1) using the hardness tester (2)

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

*BE03.20-N-1013-02B



*000589202100

If hardness value is not attained:



Replace crankshaft (1).

7

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

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

Main and connecting rod bearing journals permissible out-of-roundness variation

*BE03.20-N-1008-02B

Permissible lateral runout at fitted bearing journal

*BE03.20-N-1010-02B

Concentricity deviation measured at middle main bearing journal (support on outer main bearing journal)

*BE03.20-N-1011-02B

Engine 904

Imbalance of crankshaft (with pin for fixing flywheel but without flywheel), mounted at outer main bearings.

*BE03.20-N-1019-02B

Engine 902, 906

Permissible imbalance of crankshaft (with pin for locating flywheel but without flywheel), mounted at main bearings two and six.

*BE03.20-N-1021-02B



*001589532100



*363589022100

If values are outside tolerance:



Replace crankshaft (1).

8

Measure main and connecting rod bearing journals

 Clean crankshaft (1) bearing point with a chamois leather.

Measure main bearing journal Ø (A) with the micrometer (3) at two points
(offset by about 90°).

*BE03.20-N-1001-02B

Fit bearing journal width (B)

*BE03.20-N-1002-02B

Main bearing journal width (C)

*BE03.20-N-1003-02B

Measure connecting rod journal Ø (A) with the micrometer (3) at two points
(offset by about 90°).

*BE03.20-N-1004-02B

Connecting rod bearing journal width (E)

*BE03.20-N-1005-02B

Permissible conicity at main bearing journal and at connecting rod bearing journal

*BE03.20-N-1009-02B

Fillet radii (F) of main and connecting rod bearing journals

*BE03.20-N-1012-02B

Convexity of main and connecting rod bearing journals

*BE03.20-N-1014-02B

If damage and wear present:



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

Mounting

9

Mount crankshaft (1) radially in bearings

 Clean crankshaft (1) bearing point with a chamois leather.

AR03.20-W-4355-01B

Main bearing journal Ø (A)

*BE03.20-N-1001-02B

Main bearing inner Ø (H) when installed

*BE03.20-N-1015-02B



*BA01.40-N-1001-01C



*001589532100

10

Install crankshaft (1)

AR03.20-W-4351A

Number

Designation

Engine
902.9
with code MS8,
engine
906.9

Engine
904.9

BE03.20-N-1001-02B

Main bearing journal Ø

Default

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

BE03.20-N-1002-02B

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

Dia. 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

BE03.20-N-1003-02B

Main bearing journal width

mm

31.0...31.2

31.0...31.2

BE03.20-N-1004-02B

Connecting rod bearing journal Ø

Default

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

BE03.20-N-1005-02B

Connecting rod bearing journal width

mm

34.0...34.2

34.0...34.2

BE03.20-N-1008-02B

Main and connecting rod bearing journals permissible out-of-roundness variation

Limit value

mm

0.005

0.005

BE03.20-N-1009-02B

Permissible taper

Main bearing journals

mm

0.005

0.005

Connecting rod bearing journals

mm

0.005

0.005

BE03.20-N-1010-02B

Permissible lateral runout

Fit bearing journal

mm

0.015

0.015

BE03.20-N-1011-02B

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

mm

0.15

0.11

BE03.20-N-1012-02B

Fillet radii

Main bearing journals

mm

2.5...3.0

2.5...3.0

Connecting rod bearing journals

mm

2.5...3.0

2.5...3.0

BE03.20-N-1013-02B

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

HRC

52

52

BE03.20-N-1014-02B

Spherical shape

Main bearing journals

mm

0.000...0.004

0.000...0.004

Connecting rod bearing journals

mm

0.000...0.004

0.000...0.004

BE03.20-N-1015-02B

Main bearing inside Ø

Default

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

BE03.20-N-1019-02B

Maximum approved deviation from perfect crankshaft balance (with flywheel mounting stud, but without flywheel) at the front and rear main bearings.

gcm

-

30

BE03.20-N-1021-02B

Permissible imbalance of crankshaft (with pin for locating flywheel but without flywheel), mounted at main bearings two and six.

gcm

30

-

Number

Designation

Engines 900.9, 902.9, 904.9, 906.9

BA01.40-N-1001-01C

Bolt from main bearing cap to crankcase

Stage 1

Nm

30

Stage 2

Nm

80

Stage 3

Nm

155

Stage 4

°

90