Iveco Daily. Manual — part 93
75299
45066
Figure 79
Figure 80
MAIN CRANKSHAFT TOLERANCES
SYMMETRY
BETWEEN
MAIN
JOURNALS
AND
CRANKPINS
1.
Crankpins
2.
Main journals
3.
Normal position
Checking crankshaft
After grinding, keep to the following:
- Round off the edges of deburring the holes for
lubrication of the main journals and crankpins.
94
±
0,125
180
°±
15’
The checks on the tolerances indicated in the
figures must be made after grinding the crankshaft
pins.
NOTE
F1A ENGINE
D
AILY
350
Base - May 2004
TOLERANCE CHARACTERISTIC
SYMBOL
SHAPE
Circularity
○
SHAPE
Cylindricality
DIRECTION
Parallelism
DIRECTION
Perpendicularity
⊥
POSITION
Concentricity or coaxiality
OSCILLATION
Circular oscillation
↗
OSCILLATION
Total oscillation
↗↗
CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS
SYMBOL
CRITICAL
E
IMPORTANT
⊕
SECONDARY
⊝
75300
75302
75301
75303
75304
Figure 81
Figure 82
Figure 83
Figure 84
Figure 85
INTERMEDIATE JOURNALS No. 2-4
INTERMEDIATE JOURNAL No. 3
CRANKPINS
* On both races, on all 360
°.
- Rolling turns: 3 approach, 12 effective, 3 out.
- Rolling speed: 56 rpm.
- Decrease in crankpin race depth after rolling: 0.15 — 0.30
mm*.
- Decrease in main journal race depth after rolling: 0.15 —
0.30 mm*.
* Measured with calibrated rollers
∅ 2.5 mm.
JOURNAL ON TIMING SYSTEM SIDE
JOURNAL ON FLYWHEEL SIDE
MAIN DATA OF MAIN JOURNALS AND CRANKPINS
m
ax
.0.
1
o
n
360
°
B
e
fo
re
ro
llin
g
honed
honed
m
ax
.0.
1
o
n
360
°
B
e
fo
re
ro
llin
g
honed
m
ax
.0.
1
o
n
360
°
B
e
fo
re
ro
llin
g
honed
waviness
in circumferential direction
waviness
in axial direction
RACE AREA FOR ALL MAIN JOURNALS
(MACHINED BY TURNING)
m
ax
.0.
1
o
n
360
°
B
e
fo
re
ro
llin
g
honed
waviness
in circumferential direction
waviness
in axial direction
RACE AREA FOR ALL MAIN JOURNALS
(MACHINED BY TURNING)
Since, during the 0.254 and 0.508 mm undersizing
on the diameter of the crankpins and main journals,
the rolled portion of the side races of the pins may
get involved, it is necessary to turn the races
keeping to the data given in the figure and to do the
rolling keeping to the following instructions.
Rolling force:
- 1
st
main journal 925
±25 daN.
- 2
nd
— 3
rd
— 4
th
— 5
th
main journal 1850
±50
daN.
- crankpin 1850
±50 daN.
NOTE
F1A ENGINE
351
D
AILY
Base - May 2004
75305
75306
75307
75289
Figure 86
Figure 87
Figure 88
Figure 89
Take out the screws (4) and replace the phonic wheel (3).
The screws (4) are coated with LOCTITE 218 and must be
replaced with fresh ones after each disassembly.
They must be tightened to a torque of 15 Nm.
Replacing timing control gear
On finding the timing control gear teeth (1) damaged or
worn, remove them from the crankshaft (2) using a suitable
extractor.
The new gear is fitted onto the crankshaft by heating it to a
temperature of 200
°C for no longer than 15 minutes.
On completing assembly and after the gear has cooled, it
must withstand a torque of 150 Nm without slipping.
ENGINE ASSEMBLY
The following parts must be replaced with new ones at the
time of assembly: retaining rings, seals and gaskets, screws
whose thread is coated with sealant.
Fit on the oil spray nozzles (2) and tighten the couplings (1)
to the prescribed torque.
The main bearings (1) are supplied as spare parts undersized
on the inside diameter by 0.254
÷ 0.508 mm.
540811
Measuring main journal assembly
clearance
Mount the crankshaft (1).
Check the clearance between the crankshaft main journals
and their respective bearings by proceeding as follows:
- Thoroughly clean the pins.
- Apply a calibrated wire onto the main journals.
Assembling main bearings
Thoroughly clean the top main bearing shells (1) and position
them in the crankcase.
Not having found it necessary to replace the main
bearings, they need to be fitted back on in the same
sequence and position found upon disassembly.
NOTE
Do not do any accommodating on the bearings.
NOTE
The middle half ring (2) is fitted with thrust washers.
NOTE
F1A ENGINE
D
AILY
352
Base - May 2004
75288
75309
75310
75311
Figure 90
Figure 91
Figure 92
Thoroughly clean the bottom main bearing shells (2) and
mount them in the crankcase base (1).
Mount the crankcase base (12).
Tighten the screws in the sequence shown in the figure in
three steps:
- Step 1: with a torque wrench, to a torque of 50 Nm.
- Step 2: closing to an angle of 60
°.
- Step 3: closing to an angle of 60
°.
The end float is checked by setting a dial gauge (1) with a
magnetic base on the crankshaft (2) as shown in the figure.
The normal assembly clearance is 0.060 — 0.310 mm.
If you find the clearance to be greater than as required,
replace the rear main bearing shells carrying the thrust
bearings and repeat the clearance check between the
crankshaft pins and the main bearing shells.
If the end float of the crankshaft does not come within the
prescribed values, it is necessary to grind the crankshaft and
accordingly change the main bearing shells.
NOTE: The middle main bearing has half thrust washers
integrated in it, so it performs the function of a thrust bearing.
It is supplied as a spare part only with the normal shoulder
thickness.
α
Figure 93
- Remove the bottom crankcase.
The clearance between the main bearings and their
associated pins is measured by comparing the length of the
calibrated wire (1), at the point of greatest crushing, with the
graduated scale on the casing containing the calibrated wire.
The numbers on the scale indicate the clearance of the
coupling in millimetres, which must be 0.032
÷ 0.102 mm.
If the clearance is not as prescribed, replace the bearings and
repeat the check.
Checking crankshaft end float
Use tool 99395216 (11) for the angle closing.
NOTE
F1A ENGINE
353
D
AILY
Base - May 2004
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