Machine crankshaft

AR03.20-B-4465E

Machine crankshaft

12.02.16

Grinding

1

Check the need and possibility of grinding the crankshaft (1)

Check the crankshaft journals and define the repair stage to be ground.

 If the crankshaft presents fissures and/or cracks, replace it.

AR03.20-B-4355C

2

Remove the gear (3) from the crankshaft (1)

If necessary strike with a plastic hammer.

3

Determine the diameter of the main and/or connecting rod journals of the crankshaft to be ground

 Bearing shells are supplied only in one thickness for each repair stage (repair stage I, II, III and IV). Therefore, before grinding the crankshaft it is necessary to calculate the diameter of the journals to obtain the required radial clearance 

Main journals.

AR03.20-B-4355-01C

Connecting rod journals.

AR03.10-B-6111-06F

4

Grind the crankshaft (1) main journals

The diameter of all main journals must correspond to a same repair stage.

Diameter of the main journals (A).

*BE03.20-B-1001-02F

Width of the main bearing thrust journal (C).

*BE03.20-B-1002-02F

Width of the other main bearing journals (D).

*BE03.20-B-1002-02F

Fillet radius on the journals (F).

*BE03.20-B-1011-02F

Bulging on the journals (G).

*BE03.20-B-1012-02F

Maximum out-of-round and taper.

*BE03.20-B-1013-02F

Maximum roughness on journals.

*BE03.20-B-1014-02F

5

Grind the crankshaft (1) connecting rod journals

The diameter of all connecting rod journals must correspond to a same repair stage.

Diameter of the connecting rod journals (B).

*BE03.20-B-1003-02F

Width of the connecting rod bearing journals (E).

*BE03.20-B-1010-02F

Fillet radius on the journals (F).

*BE03.20-B-1011-02F

Bulging on the journals (G).

*BE03.20-B-1012-02F

Maximum out-of-round and taper.

*BE03.20-B-1013-02F

Maximum roughness on journals.

*BE03.20-B-1014-02F

6

Wash the crankshaft (1) and remove burrs and sharp corners n the oil holes

Utilize diesel oil or kerosene. Clean the oil passages with a cylindrical brush.

7

Check the hardness of the main and connecting rod journals, with an appropriate measuring device

 Replace the crankshaft, in case the hardness is below specification.

*BE03.20-B-1006-02F

8

Check for the need of a dynamic balancing of the crankshaft (1)

*BE03.20-B-1015-02F

9

Install the gear (3) on the crankshaft (1)

Check for condition and if necessary replace the keys (2) of the gear.

10

Install the crankshaft (1)

AR03.20-B-4351H

Número

Denominação

Engine 611.981/983; 612.983

BE03.20-B-1001-02F

Main journals diameter

standard

mm

57,940...57,965

repair stage I

mm

57,700...57,715

repair stage II

mm

57,450...57,465

repair stage III

mm

57,200...57,215

repair stage IV

mm

56,950...56,965

BE03.20-B-1002-02F

Width

of main thrust bearing

standard

mm

24,500...24,533

standard I

mm

24,600...24,633

repair stage I

mm

24,700...24,733

repair stage II

mm

24,900...24,933

repair stage III

mm

25,000...25,033

of the other main journals

mm

23,900...24,100

BE03.20-B-1003-02F

Diameter of connecting rod journal on crankshaft

standard

mm

47,940...47,965

repair stage I

mm

47,700...47,715

repair stage II

mm

47,450...47,465

repair stage III

mm

47,200...47,215

repair stage IV

mm

46,950...46,964

BE03.20-B-1006-02F

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

minimum

HRC

53...59

BE03.20-B-1010-02F

Connecting rod bearing journal width

mm

27,9...28,1

BE03.20-B-1011-02F

Fillet radius on journals

main

mm

1,9...2,1

connecting rod

mm

1,9...2,1

BE03.20-B-1012-02F

Buckle on main and connecting rod journals

mm

0...0,004

BE03.20-B-1013-02F

Maximum out-of-round and taper on main and connecting rod journals

new or machined crankshaft

mm

0,01

BE03.20-B-1014-02F

Max. roughness on polished journals

(Rt)

mm

0,0015

BE03.20-B-1015-02F

Max. crankshaft dynamic imbalance

at 500/min.

Ncm

0,1