Iveco Daily. Manual — part 21
If any traces of seizing, scoring or excessive ovalitys are de-
tected on main journals and crank pins it is necessary to re-
grind journals (2), measure crank pins with micrometer (1)
in order to determine to which diameter pins must be re-
duced.
Undersize classes are of:
0.254 - 0.508 mm.
50709
Figure 67
5408
CRANKSHAFT
540810
Measuring main journals and con-
necting rods
44035
Figure 68
RATED
VALUE
RATED
VALUE
MINIMUM Ø
MAXIMUM Ø
MINIMUM Ø
MAXIMUM Ø
RATED
VALUE
TABLE ON WHICH MEASURED VALUES OF MAIN JOURNALS AND CRANK PINS OF CRANKSHAFT
MUST BE RECORDED
It is advisable to record measured values on a table.
See Figure 68.
NOTE
Main journals and crank pins must be all ground to
the same undersize.
The performed undersize, on main journal and
crank pins, must be identified by a special printing
applied on the side of crank arm n.1.
For undersized crank pins: letter M
For undersized main journals: letter B
For undersized crank pins and main journals: letter
MB
NOTE
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Figure 69
44034
MAIN DATA ON MAIN JOURNALS AND ON CRANKS PINS
CRANKCASE, VALVE GEAR SIDE
INTERMEDIATE CRANKCASES
CRANK PINS
CRANKCASE, FLYWHEEL SIDE
Bef
o
re
rollin
g
After rolling
After rolling
After rolling
After rolling
Bef
o
re
rollin
g
Bef
o
re
rollin
g
Since when reducing by 0.254 or 0.508 mm crank pin
or main journal diameters, the rolled section of their
side grooves can be damaged, grooves shall be
turned according to data shown in the figure and
rolling shall be performed according to the following
specifications.
Rolling force:
- 1st main journal 925
± 25 daN
- 2nd - 3rd - 4th - 5th main journal 1850
± 50 daN
- 1st - 4th crank pin 1850
± 50 daN
- 2nd- 3rd crank pin 2040
± 50 daN
- rolling turns: 3 approaching, 12 actual, 3 output turns
- rolling speed: 56 rev/min
- crank pin groove depth reduction after rolling: 0.15
÷
0.30 * mm
- main journal groove depth reduction after rolling: 0.15
÷ 0.35 * mm
* measured with 2.5 mm diameter gauged pins
NOTE
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45065
45066
Figure 70
Figure 71
CRANKSHAFT MAIN TOLERANCES
SYMMETRY OF MAIN JOURNALS AND CRANK PINS
1. Crank pins
2. Main Journals
3. Normal position.
Checking crankshaft
Once grinding is completed, observe the following notices:
- Round the burr edges of main journals and crank pins
lubricating holes;
- remove oil duct sealing plugs, reface seats with a suitable
miller to remove any calking, clean ducts accurately, fit
plugs using a suitable tool (1, Figure 72) and calk them
on the relevant seats;
- make sure the plugs do not show any leakage under an
inner pressure of 1.5 bars.
S
tr
o
ke
100
±
0,125
The checks of tolerances indicated in the figures
must be carried out after grinding crankshaft pins,
if necessary.
NOTE
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CHARACTERISTIC SUBJECT TO TOLERANCE
GRAPHIC SYMBOL
OF SHAPE
Circularity
○
OF SHAPE
Taper
OF ORIENTATION
Parallelism
OF ORIENTATION
Perpendicularity
⊥
OF POSITION
Concentricity
OF OSCILLATION
Circular oscillation
↗
OF OSCILLATION
Total oscillation
↗↗
CLASS OF IMPORTANCE ATTRIBUTED TO PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL
CRITICAL
E
IMPORTANT
⊕
SECONDARY
⊝
61712
61886
Figure 72
Figure 73
Replacing gearbox input shaft centering ring
Use puller 99348004 to remove drive shaft (3) gearbox input
shaft centering ring (2).
Use a generic tool for refitting.
Should timing gear toothing be damaged or worn, proceed
with removal as follows:
- mill gear (1) in the two points indicated by the arrows,
heat the gear to a temperature not exceeding 350
°C,
then take out the gear by extractor 99348001 (2) and
block (3).
To fit the new gear on the drive shaft, the gear shall be heated
so that
≥ 200 ºC temperature difference is present between
the two parts and gear keyhole shall coincide with shaft
spline.
After fitting, under 900 N load, gear must not be withdrawn
from shaft.
Replacing timing control gear
18569
18919
18920
Figure 74
Figure 75
Figure 76
By means of ring 99360508 (1) lift engine block (2) and
secure it on rotating stand 99322205 with clamps 99361029
(3).
Rotate engine block, fit oil spray nozzles (2) with the
respective safety plates and tighten screws with a torque
wrench (1) to specified torque.
Bend safety plates on screws.
Small end bearings (1) are supplied as spare parts, with an
undersized inside diameter of 0.254 - 0.508 mm.
Assembling main bearings
Put the main bearing shells (1) with the lubrication hole into
their respective seats.
When fitting the engine, replace always: safety spring rings,
sealing rings and gaskets.
ENGINE ASSEMBLY
Max. gear heating temperature is 350
°C.
NOTE
Having not found the need to replace small end
bearings, refit them in the same order and position
they were before being dismantled.
NOTE
Do not perform any adaptation on bearings.
NOTE
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