ar0140w9271a

Widen cylinder bore in crankcase

Tyyppi ar · aihe 01.40 · versio 0128 · 2011-08-11

Koskee: ENGINES 904.941 in MODEL 684.482 ENGINES 904.904 in MODEL 670 ENGINES 904.908 /914 /923 /936 in MODELS 668, 670 ENGINES 904.9 in MODEL 374, 375, 673, 674, 676, 958, 970, 972, 975, 976 ENGINES 906.9 in MODEL 374, 958, 970, 972, 974, 975, 976 ENGINES 906.9 in MODELS 374, 375, 950, 952, 953, 954, 958 ENGINES 906.9 in MODEL 957 except CODE (MS8) Natural gas engine

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Sijainti

Toimintoryhmä 1 Moottori › 01 Moottori (kokonaisuus), moottorin huohotus, sylinterinkansi, sylinteriryhmä › 01.40 Sylinteriryhmä, jakopäänkotelon kansi, päätykansi — Mallisarja 374 · Mallisarja 375 · Mallisarja 668 · Mallisarja 670 · Mallisarja 673 · Mallisarja 674 · Mallisarja 676 · Mallisarja 684 (mallit 482) · Mallisarja 904 (mallit 9**, 904, 908, 914, 923, 936, 941) · Mallisarja 906 (mallit 9**) · Mallisarja 950 · Mallisarja 952 · Mallisarja 953 · Mallisarja 954 · Mallisarja 957 · Mallisarja 958 · Mallisarja 970 · Mallisarja 972 · Mallisarja 974 · Mallisarja 975 · Mallisarja 976

EinPAS 15 Moottori › 15.15 Polttomoottori täydellinen/moottorikotelo/kampikoneisto › 15.15.31 Sylinteriryhmä/öljynerotin/huohotus — Mallisarja 374 · Mallisarja 375 · Mallisarja 668 · Mallisarja 670 · Mallisarja 673 · Mallisarja 674 · Mallisarja 676 · Mallisarja 684 (mallit 482) · Mallisarja 904 (mallit 9**, 904, 908, 914, 923, 936, 941) · Mallisarja 906 (mallit 9**) · Mallisarja 950 · Mallisarja 952 · Mallisarja 953 · Mallisarja 954 · Mallisarja 957 · Mallisarja 958 · Mallisarja 970 · Mallisarja 972 · Mallisarja 974 · Mallisarja 975 · Mallisarja 976

AR01.40-W-9271A

Widen cylinder bore in crankcase

3.8.11

ENGINES 904.941 in MODEL 684.482

ENGINES 904.904 in MODEL 670

ENGINES 904.908 /914 /923 /936 in MODELS 668, 670

ENGINES 904.9 in MODEL 374, 375, 673, 674, 676, 958, 970, 972, 975, 976

ENGINES 906.9 in MODEL 374, 958, 970, 972, 974, 975, 976

ENGINES 906.9 in MODELS 374, 375, 950, 952, 953, 954, 958

ENGINES 906.9 in MODEL 957 except CODE (MS8) Natural gas engine

Widen cylinder bore in crankcase

I01.40-0002-06

Shown on engine 904.9

1 Cylinder crankcase

A Crankcase height

B Bore diameter (for cylinder liner in cylinder crankcase)

C Bore diameter (for cylinder liner collar in cylinder crankcase)

D Space (between cylinder liner collar seat and crankshaft bearing cap contact surface)

E Fillet radius (from diameter of the cylinder liner collar to cylinder liner collar seat in cylinder crankcase)

F Chamfer (on cylinder liner collar seat to cylinder bore)

Removing

1

Remove crankshaft

Model 684.482 * only for Indonesia

AR03.20-I-4351B

Model 374, 375, 668, 670, 673, 674, 676, 950, 952, 953, 954, 957.5/6, 958, 970, 972, 974, 975, 976

AR03.20-W-4351A

2

Remove camshaft

Model 684.482 * only for Indonesia

AR05.20-I-6292B

Model 374, 375, 668, 670, 673, 674, 676, 950, 952, 953, 954, 957.5/6, 958, 970, 972, 974, 975, 976

AR05.20-W-6292A

3

Remove oil spray nozzles

Engine 904.941 in model 684.482 * only for Indonesia

AR18.00-I-4000B

Engine 904.9 up to engine end no. 066192 except engine 904.941

Engine 906.9 up to engine end no. 067198

AR18.00-W-4000A

Engine 904.9 starting from engine end no. 066193 except engine 904.941

Engine 906.9 as of engine end no. 067199

AR18.00-W-4000C

4

Remove oil-water heat exchanger

Engine 904.941 in model 684.482 * only for Indonesia

AR18.30-I-6840B

Engine 904.9 in model 668, 670

AR18.30-D-6840D

Engine 904.9 in model 374, 375, 673, 674, 676, 958, 970, 972, 975, 976

AR18.30-W-6840A

Engine 906.9

AR18.30-W-6840D

5

Remove oil filter housing and clean

Model 684.482 * only for Indonesia

AR18.20-I-3471B

Model 668, 670

AR18.20-D-3471D

Model 374, 375, 673, 674, 676, 950, 952, 953, 954, 957.5/6, 958, 970, 972, 974, 975, 976

AR18.20-W-3471A

6

Remove compressor

Engine 904.941 in model 684.482 * only for Indonesia

AR13.30-I-5510B

Engine 904.9 except engine 904.941

Engine 906.9 except in model 957 without code (MZ9) Dual compressor

AR13.30-W-5510A

Engine 906.9 except in model 957 with code (MZ9) Dual compressor

AR13.30-W-5510B

Engine 906.9 in model 957 with code (MG7) Compressor, 2-cylinder, temperature optimized

AR13.30-W-5510E

Machining

7

Clamp crankcase (1) onto drilling tool

8

Align cylinder wall to drilling tool

With centering device above reversal point of first piston ring.

9

Clamp in boring tool

10

Drill out cylinder bore in a number of work operations

Drill out up to a bore diameter which is about 0.05 mm smaller than the specified bore diameter.

*BE01.40-N-1007-02B

When drilling out a number of cylinder liners, no two neighboring cylinder liner should be drilled out one after the other otherwise the thermal load will be too high.

Machine settings for fine boring machine
Speed: 250 to 280 rpm

Operating speed: 0.04 to 0.06 mm/revolution

11

Hone cylinder bore to the specified bore diameter (B)

Adjustment values on the honing machine:
Working pressure: 2.5 to 3.0 bar

Rpm: 60 to 100 rpm

Honing angle: 40 to 60°

Number of strokes: 30 to 40

*BE01.40-N-1007-02B

12

Check bore diameter (B) in cylinder crankcase (1)

Bore diameter for cylinder liner in cylinder crankcase

*BE01.40-N-1007-02B

Peak-to-valley height

*BE01.40-N-1012-02B

13

Bore and chamfer cylinder liner collar seat

Use a boring tool with a 90° cutting angle. The depth of the cylinder liner collar seat to be bored arises from the specified gap (D) between cylinder liner collar seat and contact surface for crankshaft bearing cap.

Distance (D) between cylinder liner collar seat and crankshaft bearing cap contact surface

*BE01.40-N-1009-02B

Bore diameter (C) for cylinder liner collar in cylinder crankcase (1)

*BE01.40-N-1008-02B

Chamfer (F) on cylinder liner collar seat to cylinder bore

*BE01.40-N-1019-02B

14

Check dimensional accuracy of cylinder liner collar seat

Bore diameter (C) for cylinder liner collar in cylinder crankcase (1)

*BE01.40-N-1008-02B

Distance (D) between cylinder liner collar seat and crankshaft bearing cap contact surface

*BE01.40-N-1009-02B

Fillet radius (E) from diameter of cylinder liner collar to cylinder liner collar seat in cylinder crankcase (1)

*BE01.40-N-1018-02B

Chamfer (F) on cylinder liner collar seat to cylinder bore

*BE01.40-N-1019-02B

Smooth operation, flatness, peak-to-valley height of contact surface of cylinder liner collar in cylinder crankcase (1)

*BE01.40-N-1014-02B

Roundness and peak-to-valley height of the bore for the cylinder liner collar in cylinder crankcase (1)

*BE01.40-N-1015-02B

15

Deburr crankcase (1) at chamfer using a polishing stone

16

Clean crankcase (1)

Check values of crankcase

Number

Designation

Engine 904.9, engine 906.9 without code MS8

BE01.40-N-1007-02B

Bore dia. for cylinder liner in crankcase (B)

mm

106.000 to 106.035

BE01.40-N-1008-02B

Bore dia. for cylinder liner collar in crankcase (C)

mm

109.572 to 109.626

BE01.40-N-1009-02B

Distance between cylinder liner collar seat and separating surface of crankshaft bearing cap (D) in all installation stages

mm

338.900 to 339.100

BE01.40-N-1012-02B

Peak-to-valley height (Rz) of drilled (honed) cylinder bore for installing cylinder liners

μm

25

BE01.40-N-1014-02B

Contact surface of cylinder liner collar in the crankcase

Radial runout

mm

0.030

Flatness

mm

0.010

Peak-to-valley height (Rz)

μm

16

BE01.40-N-1015-02B

Bore for cylinder liner collar in the crankcase

Concentricity

mm

0.060

Peak-to-valley height (Rz)

μm

25

BE01.40-N-1018-02B

Fillet radius of cylinder liner collar dia. to cylinder liner collar seat in crankcase (E)

mm

0.2

BE01.40-N-1019-02B

Chamfer on cylinder liner collar seat to cylinder bore (F)

-

mm

0.3 to 0.4

-

°

45

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