MAINTENANCE

CRANKSHAFT BEARINGS
REMOVAL AND RE-INSTALLING 02.302.03

02 1 RUNNING
GEAR Part 3
-
In conjunction with 02.302.02; 340.003101 man-hours
per cylinder unit

REMOVAL B RE-INSTALLING
TOOLS IFIXTURES IAUXILIARIES:
Torque wrench;
Pump unit VZ5495-1;
Hydraulic jack M48x3 with pipes 856 mm and 1,106 mm long

Torques:
-. @ Nut for bearing cap bolts: 140 MPa (oil pressure)
Tie rod (2) 540 Nm plus 60 deg torquing angle (wrench flat)

Marking:
Bearing shells: Cylinder No

SEQUENCE OF QPERATIONS

Safety Instructions

Conversion work by means of hydraulic jacks may be carried out

only by persons who have been instructed by the foreman in charge
or by a process engineer, on occupational safety in dismantling and
reassembling bolted joints and press fits. The workplaces in which
such conversion work is to be carried out must be inspected by the
safety engineer prior to commencement of work to make sure that
the workplace is suited for such jobs. Precautions must be taken at
the workplace to protect against oil which may be discharged at high
pressure.
Safety goggles must be worn at any rate.
When leaving pressurized hydraulic jacks unattended, put up a
warning plate reading:

CAUTION. PRESSURIZED SYSTEM.

DO NOT TOUCH.

Keep parts of the body clear of the zones above and below the
hydraulic tools as well as connecting points and joints.

Depressurize the jacks prior to disconnecting them

 MAINTENANCE
CRANKSHAFT BEARINGS
REMOVAL AND RE-INSTALLING 02.302.03
02 1 RUNNING
GEAR Part 3

1 Removal of bearing shells

1.1 Connect hydraulic jack (1) as shown in the figure while following the instructions
given in 3-00.003/01 "Tightening and loosening of bolted joints by means of a
hydraulic jack".

Crankshaft bearing with hydraulic jack

1.2 Remove tie rods (2) used to lock the bearing caps

1.3 Apply to the bearing cap bolts the pressure specified under "Torques" while allow-
ing for the safety instructions.

Back off the round nuts by means of

tommy bar to lower the bearing cap by
an amount as shown in the "Lowered
bearing cap" figure.

Remove hydraulic jack by reversing the

sequence described under 1.1 above.

Remove the bottom bearing shell.

Lowered bearing cap

5092011 E - 3-02.302103 2
 MAINTENANCE
CRANKSHAFT BEARINGS
REMOVAL AND RE-INSTALLING 02.302.03

02 1 RUNNING
GEAR Part 3

1.7 To turn out the top bearing shell install the insert (3) which comes with the tool kit,
in the oil port drilled into the main bearing journal.
1.8 Turn out the top bearing shell in the proper sense of rotation.

2 Removal of bearing caps

Whilst the bedplate is mounted, the bearing cap can be removed only by undoing
the bearing cap bolts.

3 Installing the bearing shells

3.1 To reinstall the bearing shells reverse the removal procedure

3.2 When reinstalling bearing shells used previously, care must be exercised to
ensure that they are installed in their original locations and orientation
(match-marking is recommended). The marks on the bearing shells must face the
timing gear end.
3.3 Also, care should be exercised to make sure that the bearing shells are properly
located.
3.4 Pretreat the threads of bearing cap bolts and the mounting surface of the nuts as
described in 3-00.003101.
3.5 Connect the high-pressure pipes for the bearing cap bolts by operation 1.1.
3.6 Prestress bearing cap bolt by operation 1.3.
3.7 Make the round nut hand-tight by means of the tommy bar.
3.8 Pretreat tie rods (2) as detailed in 3-00.003101 "Tightening by means of torque
wrench" and tighten to the specified torque.
- 3.9 Remove hydraulic jack by operation 1.1
3.10 Lock the round nuts by means of wire.

4 Replacing the half-rings of the t h ~ s bearing

t

4.1 Lower bearing cap by operation 1.

4.2 Turn over crackshaft such that the thrust bearing half-rings can be removed in the
longitudinal direction of the engine.
4.3 To reinstall the thrust bearing half-rings reverse the removal procedure.
4.4 Install bearing caps by operation 3.
4.5 It is recommended that. depending on the clearance 'a' described in 02.302.02,
the thrust bearing half-rings be changed in the course of an inspection of the
main bearings.
 MAINTENANCE
Crankshaft
m Checks
02.303.01

02 1 R u n n i n g gear Part 3

In conjunction with 00 300.02, 02.302 02 2 fitters / 1.0 h

to check one cylinder unit

Check: W e b run-out

Measuring tools and gauges:

Dial gauge with counteweight and special extension

As-installed clearances:

The following web run-out i s permissible on a cold engine:

Limit value when installed in a permanent installation c 0,04 mm
(with flywheel mounted)

After start-up u p t o 200 service hours on a cold engine

Increase of web run-out is admissible S 0.03 mm
(referred to the value measured on assembly in a
permanent installation prior to start-up
e Limit value of web run-out 0.06 mm

After that
* Realignment is recommended
Realignment is required

Note

The engine must be primed and cranked prior to web run-out measurement.
The web run-out is the change in spacing of a pair of crank webs during one revolution
of the crankshaft. Checking of the web run-out is necessary as to preclude "distortion"
of the crankshaft because of non-uniform tightening of the foundation bolts or because
of poor alignment relative to the driven machine, and to compensate for changes as
may have occurred during operation. "Distortion" of the crankshaft, i.e. excessive web
run-out, entails faster-than-normal wear of the main bearings or even crankshaft failure.
When excessive web run-out is detected, realignment of the entire unit is required.
Check the associated main bearings (refer to Maintenance Card 02.302.02)

Sequence of operations

Safety instructions

Never remove the crankcase covers before

the engine has been standing idle for 5 ... 10
minutes.
 MAINTENANCE
CRANKSHAFT -
CHECKS 02.303.01
-
02 1 RUNNING
GEAR Part 3

Checking the web runout

Follow the safety instructions given above.

Open safety valves as described in 00.300.02.

Remove crankcase covers on the exhaust side and the timing gearside.

Turn the crank as far as gauging point 2 in the sketch below.

Install special extension with dial gauge (clock) between the counterbalances of the
crank while using the punch marks provided there.

Set the clock to a sufficiently large value greater than zero (e.g. 20) to preclude a
reading on the left-hand side of the zero mark.

Turn the crank with the clock to gauging point l such that the clock on the con-
necting rod is just still clear.

Slowly turn the crank from gauging point 1 to gauging point 5 while allowing for the
engine cogfiguration and sense of rotation as indicated in the gauging schematic,
and
- continuously watch the deflections on the clock;
- rear the clock at gauging points 1 thru 5;
- record the readings in the DATA RECORD.
When the reading close to the gauging point is greater than the reading at the
gauging point, record the former reading.

Gauging schematic for web runout as faced from the coupling end
 MAINTENANCE
CRANKSHAFT
CHECKS

WEB RUNOUT Data Record

1.9 Determine existing web runout between the greatest and the least readings by
determining the difference for each cylinder unit.
.?-~
1.10 When the maximum permitted runout is exceeded, correct the web runout to the
"limit when installed in a permanent installation".
Marine engine: Realign the bedplate by shims.
Engine in a genset: Use shims to align the generator vertically relative to the
crankshaft. Align horizontally by moving transverse to the
centreline.
Check web runout on cylinder#l

1.11 Whe gauging the web runout, check to be sure that when starting the gauging
procedure the temperature of the clock is roughly equal to that of the engine
components.

1 .l2 Upon completion of gauging:

- Shut the safety valves as described in 00.300.02.
- Mount crankcase covers.
 MAINTENANCE
CRANKSHAFT
CHECKS
02 1 RUNNING
GEAR Part 3

In conjundion with 02.302.01; 02.302.02; manhours

02.308.01; 02.308.03 to check one cylinder unit

CHECKS: Check component condition.

Gauge clearances.
TOOLS IFIXTURES IAUXILIARIES:
Oil rubber.
Emery cloth of 40 pm grain.

NOTE:
Carry out and record clearance gauging on the main bearings according to 02.302.02, and
on the big end bearings according to 02.308.02.

SEQUENCE OF OPERATIONS

Safety Instructions

Remove the crankcase covers not until after the engine has been
standing idle for 5-10 minutes.

3 Checking the condition of the components

1.1 Remove and install main bearings according to 02.302.01, and big end beatings
according to 02.308.01.

1.2 Perfom visual inspection of main bearing journals and crankpins.

1.3 Remove undesirable phenomena such as scoring or 'elevated' material by means

of oil rubber or emery cloth of 40 pm grain.

1.4 Eliminate undesirable phenomena by checking the lube oil filtration and thoroughly
cleaning the bearing. Also, remove foreign matter from the contact areas, from the
bearing back, and from the joints.

1.5 When the condition of one bearing is objectionable, all bearings must be inspected.
 MAINTENANCE
CWNKSHAFT
REMOVAL AND RE-INSTALLATION 02.303.04
Part 3
In conjunction with 02.302.03; 340.003101; manhours
02.307.01; 03.321.01

REMOVAL AND RE-INSTALLATION

TOOLS IFIXTURES IAUXILIARIES:
Torque wrench;
Cylinder block turnover fixture;
Support for crankshaft;
Hydraulic jack with high-pressure hoses. 856 mm and 1.106 mm long

Torques:
Counterbalance bolts:
(to be installed in the crankshaft)
Oil pressure to install
Round nut for counterbalance bolt: 115 MPa
4 Timing gear: 90 MPa
with a positioning motion of 9+lmm

NOTE:
Removal of the crankshaft usually becomes necessary not until a major overhaul is due.

SEQUENCE OF OPERATIONS

Safety Instructions

Make sure to follow the safety instructions given for work on and with
hydraulic systems according to 02.302.03 and 3-00.003101.

1 Removing and re-installing the crankshaft

Having removed the assemblies (gear coupling or generator, flywheel, vibration

damper, pump drive casing, running gear unit, etc.) obstructing the removal of the
crankshaft, remove the crankshaft.

1.1 Removal upwards

1.1.1 Remove cylinder block with crankshaft from the bedplate.

 MAINTENANCE
CRANKSHAFT
REMOVAL AND RE-INSTALLATION 02.303.04

02 1 RUNNING
GEAR Part 3

1.1.2 Turn the unit in the turnover fixture thru 180 deg and place on a wooden support
with the cylinder head top down.

1.1.3 Remove main bearing caps according to 02.302.03.

1.1.4 Remove crankshaft upwards.

1.2 Removal downwards

1.2.1 Mount the support for crankshaft (this fixture is available as an option) at the ~-
coupling end and at the opposite end of the main coupling of the bedplate.

1.2.2 Slacken the nuts of all main bearings in a stepwise procedure according to
02.302.03. This lowers the crankshaft onto the support.

1.3.1 Thoroughly flush the lube oil ports in the crankshaft by means of fuel.

1.3.2 To re-install the crankshaft reverse the removal procedure. Care should be
exercised to ensure that the crankshaft is perfectly clean.

1.3.3 Install the main bearings as described in 02.302.03.

2 Removing and re-installing the counterbalances

2.1 Removal

2.1.1 Turn the crankshaft such that the counter-

balances are normal to the joint between the
cylinder block and the bedplate.
/
2.1.2 Connect the hydraulic jack to slacken the round
nuts of the counterbalance bolts as shown in the
Figure "Counterbalance with hydraulic jack", and
according to the instructions given in
3-00.003101 "Tightening and loosening of a
bolted joint by means of a hydraulic jack".

Connect high-pressure pipes of the specified

length.
Counterbalance with
hydraulic jack
 MAINTENANCE
CRANKSHAFT
REMOVAL AND RE-INSTALIATION 02.303.04

02 1 RUNNING
GEAR Part 3

2.1.3 Apply the oil pressure specified under "Torques" above, to the counterbalance bolts
while following the safety instructions given.

2.1.4 Slacken round nuts by means of the tommy bar.

2.1.5 Disconnect hydraulic jack as described in 3-00.003101

2.2 Installing

2.2.1 To install the counterbalances reverse the removal procedure. Make sure to locate
..
the counterbalances by means of locking pin.

2.2.2 Do not forget to allow for the match-marking on crank web and counterbalance

2.2.3 Pretreat the threads of the counterbalance bolts and the seating surfaces of the
round nuts as detailed in 3.00.003101.

2.2.4 Connect high-pressure hoses by operation 2.1.2, and apply the specified oil
pressure to the bolts.

2.2.5 Make the round nuts hand-tight by means of the tommy bar

2.2.6 Remove hydraulic jack as described in 3-00.003/01

3 Installing new counterbalances

3.1 To install new counterbalances proceed as described in Operations 2.2.1 thru

,.-,
2.2.6.

3.2 - When changing one or a number of counterbalances

(but not all of them), the weight difference when
compared to the counterbalances still in the engine
must not exceed 100 grammes.
When placing orders for counterbalances, do not forget
to specify the weight range indicated on the counter-
balances.

- When changing one, several or all counterbalances,

care must also be exercised to ensure that the weight
difference between the running gear units is within the
tolerance specified in 02.307.01
 MAINTENANCE
CRANKSHAFT
REMOVAL AND RE-INSTALLATION 02.303.04

02 1 RUNNING
GEAR Part 3

4 Installing new counterbalance bolts

Torque the counterbalance bolts to specifications.

5 Changing the timing gear

5.1 Replacement of these components, provided the engine operates under normal
conditions, will become necessary not until a major overhaul is due.

5.2 If, however, an earlier replacement is required, proceed as detailed in 03.321.01,

Operations 2.3 and 2.5 "Changing cams".
The procedure of connecting the hydraulic jack is shown in the following Figures: --
"Timing gear with hydraulic jack"
* "Hydraulic pump unit connected to the crankcase opening" .

Lock washer (A) must be fitted

during mounting and removal.

Timing gear with

hydraulic jack

K = Connection of H.P. hose

Hydraulic pump unit

connected to the
crankcase opening

5.4 Having installed the timing gear, it is essential

that the timing angles be checked.