ne 11. Crank Mechanism: Wl Crankshaft, Connecting Rod, Piston Counterbalancing of crankshaft 11.1.1 General ‘The crankshaft is counterbalanced by means of weights on the crane ‘webs. The in-line engines normally have counterweights on one web per cylinder, the V-engines on all webs, 11.1.2 Counterbalancing of 4-cylinder engines ‘Thesecond-order free forces of¢-cylinderin-ine enginesare completely counterbelanced by means of an arrangement consisting of two eccen- ‘ric shafts rotating in opposite directions in relation to each other. The shafts rotate at a rate of twice the engine speed. The centrifugal forces ‘counteract each others horizontally and counterbalance the free forces of the engine vertically. "The shafts are pivoted in the bearing brackete, which are fastoned to theengine bloctby means ofhydraulically tightened screws. Theshafts are driven from the crankshaft split gear through a gear drive. ‘For further information see section 11.4. 11.1.3 Counterbalancing of 9-cylinder engines "The 9-cylinder incline engines differ from the other engines in that they hhave counterweights on all webs. Furthermore, the utmost counter- ‘weight at each end of the crankshaft is larger than the other ones and ‘unsymmetrical in order to counterbalance the free moment of the engine. When such a counterweight has been removed from the engine, itis ofthe greatest importance that itis correctly re-installed, Fig 11-1. 11.1.4 Cour balancing of 1 ‘The counterbalancing of the free moment ofthe 18-cylinder V- engines is accomplished by means ofa supplementary weight a the free end of ‘the engine and a specially balanced flywheel. After a possible emoval, ‘Eis imprint that he mpplementry weight corresty ral 112,‘Mounting of counterweights on 9832 one Seen fom fywheel end gt Supplementary weight for 18V32 ‘Crank web foreyinder A * Soa 8) fe shaight upwards Cemienine of * Fora clockwise rotating engine: Croniehat is time! 10.29) efter TDC for eyindee AT Fer o,counter cockwae fotng ange: Crankshaft is tumed fo 25; before TDC for cylinder Al Fig 11-2 a W-212 Crankshaft 11.2.1 Description of crankshaft ‘The crankshaft is forged in one piece and provided with counter- weights fastened with hydraulically tensioned screws. “At the driviag end of the engine, the crankshaft is equipped with a ‘Vering for sealing off the erankease,acombined flywheel thrust bearing and a split gear wheel for camshaft driving ‘At the free end, there is a gear for driving of pumps and usually a vibration damper. If power is taken off at the free end, sealing of the crankshaft is arranged by a V-ring, as at the driving end. "The crankshaft can be turned by a electrical turning device operating ‘the Oywheel, Separate instructions for the vibration damper are sub- mitted, ifthe engine is equipped with such, 11.22 Crankshaft alignment ‘Thecrankshaf alignments always doneon athoroughly warm engine, immediately after the engine is stopped. The crankshaft alignment should be carried out rapidly but carefully. Only the crankcase cover for the cylinder being measured should be opened and it should be closed immediately after measuring. Hi tum crank of the first cylinder near BDC (bottom dead centre) and attach crankshaft dial indicator to the centre marks in the two crank webs, The distance between the indicator and the connecting rod should be as small as possible. i set indicator at zero. Dial indicato: postion and reading coamg ich) 9) ear sto ‘Ass90n tom frweot end Fig 11-3 — nesMANES Wea Note! Note! Read deflections when turning crank to rear side, TDC (top dead centre), operating side and BDC. Record readings in the form “Crankshaft alignment” During the alignment procedure the crankshaft should be tuned in the direction of rotation, only Repeat this procedure with other cylinders. [E1 Following limits of misalignment sre stated for an engine hav- ing normal running temperature (within 10 min aftr runaing at 60% load, or higher, for Gi, or more: ©) on the same crank, the difference between two diametrically ‘opposed readings must nt exceed 0.04 mm after installing or r-align- ing Re-lignment is necessary i this limits exceeded by more than 0:02 mm, ) on two adjacent cranks the difference between two corspond- ing readings must not exeeed 0.04 mm. Re-alignment is necessary i (his limit i exceeded. ©) when the crank pin for eyL.1 is at TDC, the reading should be negative, max. 0.04 im (0.06 mm iflex. coupling) ‘Before re-aligning the engine and the driven machinery, a control measurement of the main bearings should be made. In an engine having a normal ambient temperature, the cor sponding values mustbe based on experiences from the particular installation. .3 Measurement of thrust bearing axial clearance EB Lubricate the bearings by running the prelubricating pump for a few minutes. 1 Appiy.a measure gauge, for instance, against the plane end surface of the fywheel. Move the crankshoft by a suitable lever in either di “until contact is established with the thrust bearing. ‘Set the measure gauge at zero. 1 Nove the cronkshatt in the opposite direction, and read the axial clearance from the measure gauge ll Remove the outer plug (1), Fig 11-4.11.3 Note! 1 Blow through the bores of the oil lock from outside with com- Dressed air. ‘There is no need for refilling the ol lock with oil after cleaning. Olllock at crankshat seal 1. Plug | Fig 11-4 ‘eno Connecting rod and piston 11.3.1 Description of conne ing rod and piston ‘The connecting rod is drop forged, diagonally split and precision serrated at the mating surfaces. The big end bearing shells are, for correct assembling, axially guided by lugs, and the two connecting rod screws are hydraulically tightened. The small end bearing bush is stepped to give a larger bearing surface on the more londed lower side. ‘The piston is of castiron monoblock type or ofthe composite type with, 4 nodular cast iron skirt and a forged steel crown screwed together. ‘The space, formed between the crown and the skivt, is supplied with lubricating ol for cooling ofthe crown by means ofthe cocktail shaker effect. The lubricating ol is led from the main bearing, through the drilings in the crankshaft, tothe big end besring, and further through the drillings in the connecting rod, gudgeon pin and piston skirt, up to the cooling space, and from there back tothe oil sump. ‘Always handle the pistons with care. ‘The piston ring set consists of three chrome-plated compression rings and one spring-loaded ol seraper rings.2.Serew 3. Securing fing 11.3.2 Removing and dismantling of piston and con- necting Remove the eylinder head and scrape off carbon deposits around the upper part ofthe eylinder liner Its advisable to cover the piston tep with cloth or paper pressed tightly against the evlinder wall collect the deposits removed i Remove the anti-polishing ring. Use the tool if necessary. By ‘turning the engine, the piston pushes the anti-polishing ring out. Clean the threaded hole(s) in the piston crown and fasten the ing tool 2V83F58 by using hexagon screws M12°50 (2). Piston and H-profile connecting rod assembly 2 ess 4, ~ 1e4D11 Risa 3ve68139 ‘V2 3V86B136 R32 Svee8102 | Fig 11-5 ‘Tum the crankshaft from TDC towards the operating side for the cylinder concerned, on in-line engines 106 - 110°, on V-engines an n-6Note! Note! Note! tion on the connecting rod screws and screw on the hydraulic tools 3V86B139 with extension pieces 3V86B137. ‘V-engines: Lif: the distance sleeves $V86B136 into gosition on the connecting rod screws and screw on the hydraulic tocls 3V86B139, Ei Connect the hoses of the hydraulic pump t 2V&6A36 and. proceed to open the connecting rod nuts, 1 Remove the hydraullc tool and the distance the upper serew. El openthe upper nut and screw the too! 3V80D200n the upper bbolt. The locking screw ofthe tool has left-hand threads. eve from ‘When using the stud remover 380020 only the inner hexagon 27 key grip should be used when the stud Is removed cr tightened to tora, The outer fe hand hexagon 24 scrow is nly Tor asking the fool onto the stud and will break if used fo loosen the Bolt. 1 remove tne upper bot and place the dismanting screw SVSGRO4 In vo space Lock he bearing cap ofthe nection rod ‘ith the locking nut VEO, ID remove the nycrauite tool and ne dstance sleeve from the lower bultand fomove tne bt with ol SVSODE). iI on in-line engines. Open the locking nut and remove the big end bearing cap. On V-engines, fit the tool 1VE4G236 to the crankcase cover lower studs, and tighten the nuts, see Fig 11-6. Pull the tool lever outwards and remove the locking nut. Remove the big end bearing cap by moving the lever inwards. Lift the bearing cap fut of the tol, Remove the tol from the studs The too! 1846236 Is for V-engines only. TE. remove the clemanting serew. Lit the piston a ite to remove the upper big end bearg Shell. On Veengines, ft she protecting sleeves SVSSFS2. and 2VEBPES nto postion above the connecting rol seraion, see Fig 116. When lifting the piston, take cae not to damage the crank pit or the cylinder line wal BE cover pin oll holes wth tape. IE] remove the secutng ing (8) from the gudgeon pin hole in fhe piston, onthe side where the gudgeon pin drawing number is located, by using the pliers J5. Never compress the securing ting more than necessary to remove Itfrom the groove. Ne?Emer drive out the guaigoon pin from the opposite side. Inlow tem- peratures the gudgeon pin may stick but willbe easly removed ater heating the piston to about 30°C. Itthe rings and grooves require cleaning, measuring etc., remove the piston rings by using the pliers $20D1216-$7/8. Before removing, note the postions of the rings to ensure mounting in the fame grooves. The design ofthe pliors provents overstressing of the rings, Using other means may overstress the rings Tools for rofle connecting rod Fig 11-6 suse fon, rings and connecting rod Clean al he parts carefully. Remove the piston rings, and re- move buraed carbon deposits fiom the piston and piston ring ‘grooves. Special care should be taken not to damage the piston material. Never use emery cloth on the piston skirt, The cleaning is facilitated i coked parts are soaked in kerosene or fac oil. An efficient carbon solvent — e.g. ARDROX No. 668 or similar — should preferably be used to facilitate cleaning of the piston erowa. When using chemical cleaning agents take are not {oclean piston skirt with such agents because the phosphata/graph- Ite overlay may be damaged. ,Measure he height of the piston ring grooves, e.g. with an Inside micrometer, Inspect ant-polshing ring. Turn the ring upside down after first periol, Change the ng every second periodplaced Gi Check the gudgeon pin and big end bearing clearances by measuring the pin diameters and assembled bearing bores sep rately. When measuring the big end bearing bore the connecting rod screws must be tightened to the stated pressure, (©) Big end bearings of trimetal type can be used until the overlay is worn through. When the underlaying nickel barrier of the lining. material is exposed the bearing must be replaced, b) Wear of bimetal bearing shells can be settled by meesuring ‘thickness, For this purpose & ball anvil micrometer should be used. For bimetal-type bearing, the wear limits given in chapter 062 must. be applied. ‘When replacing a big end bearing both the upper and the lower bearing shell must be renewed. ‘Mark new beatings with the bearing number. Its very important that the bearing shells are mounted straight. 11.3.4 Assembling and mounting of piston and Connecting rod IH Lubricate the gudgeon pin, and mount from the same side from where it was removed, with the end marked with the drawing ‘number in the same direction. The cylinder nunber is stamped on the piston erown and connecting rod, Fig 11-5. When changing the piston, mark the new piston with the same cylinder number in the Same plece as on the replaced one. ‘At low temperatures, the gudgeon pin may stick but will be easily fitted after heating the piston to about 30°C, ein oil, 1 ount the securing rng Never compress the securing ting more than recessary to Mino: the groove. if the ting Is loose in lis groove ater mounting, it must bbe reploced by a new one.EX Take off the protecting tape from the crank pin oil holes and Iibriate the erank pin with clean engine oi Fasten the litng too! 2V8258 to the piston crown by using hexagon socket head serews M1250 (2), see Fig 1-3 Tum the crankshaft from the TDC towards the operating side for the cylinder concerned, onthe in-line engine 116 110° oh the ‘Veengine 84. On the V-engine, fit the upper bearing shell with the Tog guidingin ta groove and protectngrale SVSFOz and ZVQ318S info positon, Fights Lif the piston and connecting rod. Mount the piston rings by using the pliers 320D12/6-S7/8. If Finge are reused take care noo turn them upside down. The rings Should be placed with gaps located 120" in relation fo each other. ‘The marking “Top” tobe apwarde Piston ring locations shown in the table below. 1 “IOPC746ROOVE n “Tor car” | W TOPCS2" | I v (Clserepertna) J 1 ubricate the piston and place the clamp device for piston Sings, 1VB4D11, around the piston, checking that the piston ings slide into thelr grooves H1 When cylinder ners equipped with a anti-polishing ring, place the mounting tool 2V83F108 into the eyinder ine. Lower the piston/connecting rod carefully into the cylinder Tiner. Bi] Lubricate ine bearing surface and both ends of the upper Dearing shell I'the bearing shell is a bimetal bearing, the back side af the shell must also be lubricated with a thin layer of clean engine oil, Mount the shell ofthe in-line engine, so that the lug guides in its groove EB. tower the piston further until the connecting rod can be placed on the erank pin Fosten the assembly screw 3VS3B84 to the upper thread of the connection rod TZ) Uubricate the bearing surface and both ends of the lower bearing shell end place the shell inthe bearing eap. Ifthe bearing shell isa bimetal bearing, the back side of the shell must also be Tubricated witha thin layer of clean engine oll N1011.4 Ff] Litt tne bearing cap on the assembly screw and slide in ‘Smoothly towards the connection red. On the V-engine, tthe tool 1V84G236 to the lower studs of the crankease cover snd tighten with nuts, soe Fig 11-6 It the bearing cap so, thatthe serrations ere in the right relative position. Ills very important that the bearing shells are mounted straight. 1 Tiohten the locking nut 48385 to keep the bearing cap in contact with the connection rod, BE Mount ne lower bolt and tighten the nut by hand. After tightening, remove the assembly sere from the upper threads. BB) Mount the upper bolt and nut and tighten both bolts with the tool 3V80D20 to torque. i] Lit the distance slooves 8VB6B102_ in-line engines) oF ‘SV86B136 (V-engines) and the hydraulic tools 3V86B199/137 into position, and proceed with tightening of connecting rod nuts. ‘Check that the connecting rod is movable axially ater tightening. Mount the anti-polishing ring, Balancing shaft mechanism for 4-cylinder engines ‘The second-order free forces of the ‘cylinder inline engines are completely counterbalanced by means of an arrangement, according to Hig 11-7, consisting of two eccentric shafts rotating in opposite direc. tions in relation to each other. The shafts rotate at a rate of twice the ‘engine speed. The centrifugal forces counteract each others horizon- ‘ally and counterbalance the free forces of the engine vertically. ‘The shafts are pivoted inthe bearing brackets (2), which are fastened to the engine block by means of hydraulically tightened screws. The shafts are driven from the crankshaft split gear through a gear drive. 11.4.1 Removal of balancing shaft bearing bush I Tun he engine ins «position where the balancing shal ec entries point downwards.1-ganeng sont isongece ats ey 28. boorg sets a.bive gear Is:louna He W-12 Rod, Piston) 1 Loosen the nuts (6) and (6) and remove the shatt piece (3) {tom the shat the bearing of which is tobe removed. Loosen the screws (7) and remove the shat flange (4). Balancing shaft for 4R32 2 Fig 1-5 ava ‘Screw on the pulling screw 3V83H71. see Fig 11-8 A. to the fend of the shaft from which the bearing i to be removed, When removing the bearing at the free end of the shaft, remove the centre plug (8) at first. Fit the spilt ring 3V83H70 between the bearing and the shaft inner shoulder. In order to keep the ring halves together, use e.g. Suitable thread and place it in the groove, on the ring. Ei Appiy the support 2V83H148 and the hydraulic tool SV83E61 and tighten the nut ofthe pulling serew SV8SH71. ' B connect the hoses of the hydraulic pump 2V86A36 to the hydraulic tool. El Pump pressure into the hydraulic toa to remove the bearing bush. Pressure must not exceed the value stated in the chapter 07, Fig 07-14. If the bearing bush is still sticking when the stated pressure Is achieved, it may be necessary to knock at the opposite fend of the chat 1 open tho pump valve, disconnect the hoses ofthe hydraulic {ool and lif out the removing tol snd bearing bush, Now the shaft fend rets in the split ring which must not be removed until the bearing bush is re-installed.Balancing shaft bearing bush E9661 383470 \svesu7] vasa [svasut (avasrs svesned A 8 Fig 11-8 i 11.4.2 Installing balancing shaft bearing bush Il screw in the pulling screw 3V83H71 into the end of the shaft ‘to which the bearing isto be mounted. B Piace the split ring 3V83H84 between the bearing housing 3nd the oulor shaft shoulder. Keep the ring halves together by eg. suntable thread 1 Oil the bearing bush surfaces lightly with clean engine oil and place the bush on the shaft end. 1 Apply the pressure plate 4V83H83 and the hydraulic tool ‘3V89H61, and tighten the nut of the pulling screw. [i Connect the hoses of the hydraulic pump 2V86A36 to the hydraulic tol. [Ei Pump pressure into the hydraulic tool to press in the bearing ‘bash, Presture must not excoed the value stated in shapter 07, Fig 07-14. The bearing is in position when the pressure plate 4VESHES rests against the bearing housing EZ Open the pump valve, disconnect the hoses of the hydraulic fool and remove the tools Lock the centre plug (8), Fig 11-7, in the free end ofthe shaft with Loctite 270 and tighten to the boitom posit in case it was removed. EZ Fe-instal the shaft flange (4), clean thresds of fastening: serews (7) thoroughly and apply Loctite 242 to them. I Tighton ho screws (7) to the stated value n-13ne II] Fo-insiall the shat piece (3), clean the threads ofthe fasten- {ng screws (6) thoroughly and apply Loctite 242 to them. 1 Tighten the scrows (5) and (6) tothe stated torque. 3 Removal of balancing shaft gear IHL tum the engine into a position where the balancing shaft ec- centries point downwards, 1 Loosen the fastening screws (22) of the axial washers (11) at the free end of the shafts, Loosen the scrows (6) and (6) and remove the shaft pieces (8) Pullout the driving shatts (13) and the drive gears (14), 1 Loosen the fastening screws (10) of the bearing shield (9) at all intermediate gears. The main bearing eap No. | must be lowered before undoing the fastening screws of the topmost intermediate gear. Seo chapter 10, section 10.2.1 Tl Remove the bearing shield (9) from the bearing journals by tightening the M8 screws in the extra:tor holes ofthe bearing shield ‘Tighten the screws in turn and as evenly as possible Remove the topmost intermediate gear. To do this, the main bearing cap No. 1 must be lowered. To remove the rest of the intermediate gear, lift the main bearing cap No. 1, See chapter 10, section 10.2.3. u 4 Installing balancing shaft gear Il Oil the siding surfaces of the tearing bushes with clean en- ine ol. 1 fit tne intermediate goars (17) on their respective journals (13), For fitting of the topmost intermediate gear, lower the main Ihearing eap No 1 Ro-insill tho bearing shield (9) and washers (16), and tighten the fastening screws (10) by hand Tighten the fastening scrows (10) in turn at the intermediate gears and as evenly as possible. Ei Tighten the fastening screws (10) to the stated torque and se- cure with locking wire [i tum the ongine so that cylinder 1 is in TDC or BDC. In these positions, the balancing shaft eccentrics should point downwards, ‘Now all the guiding pins between the shaft pieces are also in the bottom position.[ee Rotel tho diving shafts (12) and drive gears (14) in their ‘eapestive bearing sites the genes will mesh when the guding in Shoe inthe shaft Mange is right downwards EI Ro-intal tho shat pioces (3), clean the threads ofthe fastn- ing screws (6 thoroughly and apply Loctite 242 0 them, El Motion th serows (5) and (6) to the sate orque Il] Fhe oxil washers (11) and che fastening. screws (2) Tightsnto torque stataltn chepter 07 end socarevaith locking wire. [Notel Alternative design witha locking washer. 11.4. Removal and re-installation of balancing Bearing bracket ‘Normally, these connections should not be opened. The bearing brack- ets can, however, be removed by opening the screw connections by ‘means ofthe hydraulic tool SVB6B78, which is used far, among others, the connecting rod screws, see chapter 11, section 11.3°2. ‘When re-installing, the serews are tightened to the value stated in. the charter 07. by using the same tool 1-15EID