SECTION 6 CRANKSHAFT AND ACCESSORIES CONTENTS CRANKSHAFT DESCRIPTION INSPECTION CHECKING MAIN BEARING STEEL BORE DIMENSIONS ANSTALLATION MAIN BEARINGS DESCRIPTION SCHEDULED RENEWAL INSPECTION REMOVAL AND APPLICATION CRANKSHAFT THRUST COLLAR DESCRIPTION MAINTENANCE, VISCOUS DAMPER DESCRIPTION MAINTENANCE 36974 63 63 o4 65 6-6 66 66 66 contents ACCESSORY DRIVE GEAR DESCRIPTION MAINTENANCE PHOSPHATE TREATMENT ASSEMBLY ACCESSORY DRIVE HOUSING APPLICATION AND ALIGNMENT RING GEAR AND COUPLING DISC DESCRIPTION MAINTENANCE AUXILIARY DRIVE COUPLING DESCRIPTION MAINTENANCE, SERVICE DATA SPECIFICATIONS: EQUIPMENT LIST 67 o7 68 68 6-10 610ENGINE WAINTENANCE MANUAL, SECTION 6 S4A,Re SUPPLEMENT NDq 1 ‘INSTRUCTIONS: CRANKGHAFT AND ACCESSORIES: FEFERENIE 2 ENGINE CRANIGHAFT REPAIR PROCEDURE ~ DAMAGED FRONT-END TAPER: ON CRANKSHAFT te Remave crankshaft from engines 2. Part off damaged front teper from front-end boss of crankshaft. 3e Bore end turn hole in front-end boss as per drawing 8294115, 4. Wenufecture taper stubshaft es per drawing 6293712. Se Press stubshaft into front-end boss using procedure described on drawing 8294115, 6, Use coupling assembly 8323180 as a taper gauge ta determine accu. Fecy of taper ground inta stubshaft, FEF. xh 15/4/28/2 of 27 September 1978FEM SERVICE OEPARTMENT MANUAL ENGINE MAINTENANCE SECTION 6 CRANKSHAFT AND ACCESSORIES CRANKSHAFT DESCRIPTION 6-1, is a drop fonting of carbon stecl material with induction hardened main and crankpin journals. On 8 and 12-cylinder engines, the crankshaft is a one piece Forging. On I6-eylinder engines, the crankshaft is made up of two sections whose flanges are bolted together Counterweights are provided to give stable oper ation and all crankshafts are dynamically bak anced. Drilled oil passages provide for lubrication of the main bearings as shown in Fig, 6 The crankshaft, Fig, waters O12 fort? Accessory Drive End Foor MAINTENANCE INSPECTION Whenever the main or connecting rod bearings are removed, the crankshaf! journals should be in- spected. Check for scoring and cracks, and signs of distress, as will generally be evidenced first in the bearings. When the crankshaft is removed from the engine, it should be visually and dimen- sionally inspected, and magnaftux inspected if possibie, The journals of the crankshaft are induction hardened, Excessive heat resulting from lack of Furbo Camshatt Gear End Bac 12-0ylinder 16-Cylinder Fig. 6-1 ~ Engine Crankshaft saezra otSection 6 Main Bearing Main Bearing Fi. 6-2 — Crankshaft Oil Passages lubrication, insufficient bearing clearance, or other causes will usually produce thermal cracks fon the journal, Damaged crankshafts can usually be reconditioned st EMD to reestablish journal size and condition to use standurd size bearings. In some instances, crankshatts may have to be reground requiring the use of undersize bearings. Altempts to grind crankshafts in the Sletd have proven unsuccessful, as during the tegrinding process, the depth of the induction hardened zone must be checked, and when necessary, re- hardened. ‘This requires special induction harden- ing equipment. It is therefore recommended that the crankshaft be returned for grinding. To aid identification, reground crankshafts with under- size journals or oversize thrust bearings will have this information stamped on the same cheek as the seriat number. CHECKING MAIN BEARING STEEL BORE DIMENSIONS At time of crankease overhaul, or whenever crankshaft is removed from an engine, it is neces- sary to determine whether main bearing steel ore dimensions are within tolerance. NOTE: Dimensional wear limits are contained in Service Data at the end of the section 1. Place the crankcase on its side to facilitate application of the crankshaft Be sure that the crankease "A" frame bores and serrations are clean, 3. Lubricate the studs, nut sests, and hardened washers with Texaco Threadtex No. 2303 or equivalent. CAUTION: Use of the hardened washer under the main bearing cap aut is mandatory to ensure proper bolt stretch and to nut torque, Damaged nut seat areas on the caps must he cleaned by spot-facing or by tuking a cut (1/16" maximum depth) parallel to the serra tion surface 4, Apply the main bearing caps, and torque the nuts in two passes. On the first pass, torque the nuts to 350-400 ft-lbs. On the second pass, final torque the puts to 750 ft-lbs, NOTE: No one nut_on any one cap should be torqued to 750 ftibs until all nuts on that cap have been torqued to 350-400 fllbs. NOTE: A procedure using stud stretch measure- ments as the criteria for monitoring tor ques when the engine is disassembled and on its side is available from your EMD service representative. 5. Check that the main bearing bore dimezsions are within the minimum, and maximum limits. 2961273Take (wo sets of measurements at cach bore, one set 1/2" in from the accessory end of the bore and one set 1/2" in from the generator end of the bore at points shown in Fig. 6-3 meee ce Jf Fig, 6-3 ~ Main Bearing Bore Measurement 6.If any one diameter is out of tolerance - a, The crankcase may be shipped to EMD. for remanufacture b. if the engine owner has facilities for crankcase machining and wishes to do his ‘own remanufacture, contact the EMD. service representative for information con cerning control of main bearing steet bores during se:zanufacture, INSTALLATION 1. Apply the main bearings to the frame bores and to the bearing caps, lining up the bearing tangs. NOTE: See "Main Bearings” for quatitication of bearings, ZAnspect the crankshalt and be sure it is clean. Oil the crankshaft journals and main bearing, shells, using clean oil, Place the crankshaft in the "A" frame bearing, shells and apply the two cnd and two center (Clé-cyl.) bearing caps to hold the crankshaft in place, Check that the studs, mur seats, and washers ate lubricated and secure the caps. Tighten the nuts until they contact the bear ing caps. Remove the hoist or crane hooks. Place the thrust collars in their respective "A" frame counterbores, as shown in Fig. 6-4, and apply the remaining bearing shells and caps Manually tighten the nuts until hardened washers are seated on bearing cap. 2981213 63 Section 6 Ot Depression I Fig. 6-4 ~ Applying Thrust Collar (16-Cy1.) 6. Using a power wrench, all nuts are torqued (0 350-400 flibs. After all puts have been tight- ened to this torqae, final torque nuts to 750 fiibs. Do NOT overtorque. NOTE: No one nut_on any one cap should be torqued to 750 ftlbs until all nuts on that cap have been torqued to 350-400 felbs. MAIN BEARINGS DESCRIPTION The main bearing shells, Fig. 6-5, are precision type steekbacked lead-bronze, with a thin layer of lcad-tin. Tangs in the bearings locate them in Fig. 6-5 ~ Main Bearing Shells And CapsSection 6 the proper axial position and prevent bearing turning. Upper and lower bearing shell halves are not interchangeable. Lower main bearing shells have two tangs on cach side which fit into the main bearing cap. Upper ‘main bearing shells have one tang, whieh fits into 4 groove on the right side of the "A" frame bore Upper shells can be rotated out, in a direction opposite to normal crankshatl rotation, when the lower bearing and cap are removed MAINTENANCE SCHEDULED RENEWAL Lower main bearings should be renewed at the intervals specified in the Scheduled Maintenance Program, Upper main bearings need not be removed when lower main beatings are renewed unless the Iower beurings show detinite signs of distress. Upper anged out individually as required, not in sl INSPECTION UPPER MAIN BEARINGS Inspection of upper main bearings is not revom- mended; however once the upper main bearings are removed, they should not be reinstalled. LOWER MAIN BEARINGS Lower main bearing inspection should be_per- formed only when necessary as an element of risk is involved whenever main bearings are disturbed, WARNING: If an engine has been shut down by the crankcase pressure detector, do NOT open any handhole or top deck covers to make an inspection until the engine has been allowed to cool down for at least two hours, The aetion of the pressure detector indi- cates the possibility of a condition within the engine, such as an over- heated bearing, that may ignite the hot oil vapors with explosive force if air is allowed to enter, After the engine is cool, make a thorough and careful engine inspection I. The lower main bearings should be inspected when abnormal conditions are observed in the engine, such as contamination of lube oil due to dillution with fuel or water, or the pre= sence of foreign material in the lube oil Fitters, sereens, or engine oil pan. 2. Lower main bearings need not be inspected in routine service, but should be renewed at the intervals specified in the Scheduled Maintem ance Program. INSPECTION SAMPLE Unless evidence is present calling for other action inspection of main bearings should be limited to the following "selected lower shells” which ex perience hus shown 0 be the most critical. See Fig. 6-1 for main bearing numbering location Number Of Bearing Number Cylinders To Be Inypected 24 2 26 16 269 DISQUALIFICATION CRITERIA All lower main bearings are to be renewed if any one lower main beating is disqualified at any one of the “selected” bearing locations, above, or at any additional toca for other reasons. ‘The following numbered paragraphs ive examples of conditions requiring renewal of all lower main bearings. 1, Any one bearing shows evidenee of overheat ‘An overheat condition results m Mowing of the overlay, and discoloration of exposed bronze. (An upper main bearing is to. be renewed when the corresponding lower bear ing shows evidence of overheat.) 2. Any one bearing fon the overlay. tremely thin contamination.) shows a milky white color (This is evidence of an ex- overlay and indicates water 64 e9763. Any one bearing has 1/8" of more wide runnin, edge. or if two or more beatin any exposed bronze. NOTE: The feat-tin overlay on the bearings must be present 10 provide an adequate safety purenin against temporary. margins Iubri- cation or corrosive conditions. Exposed bronze in healed dirt cuts does mot affect bearing operation, but exposed bronze due to wear does cause a bearing t6 bose its protection against temporary marginal lubrication conditions. 4. Fxposed bronze due to isolated abnormal wear or overlay Maki Severe fretting along the mating edge of the upper and lower besring, (The corresponding upper bearing should be renewed at any fogs tion exhibiting severe fretting, and bearing, cap serrations inspected tor possible damage.) Severe dirt seratehes or dirt resttlting in an abrusive surface, mpregnation CAUTION: Dirt impregnation or scratches are evidence that bearing oil is not prop- erly filtered, The Filtration system. should be checked, and scheduled presstite monitoring of lube oil filter conditions established INSPECTION PROCEDURE ‘A visual inspection is made by dropping the bearing cap, with the bearing in it, low enough to ke the inspection without removing the cap from the studs or the bearing from the cap. Removal of a reusable maint bearing from the cap may result in improper rescating. Bearing removal also allows the possibility of replacing the bearing position or at the wrong joumal location, Either condition ean lead to carly fail ure. In addition, removal of the eap from the studs involves the risk of damage by dropping and the risk of replacing the cap backwards. iy. inadvertently inspection, perform removed the If a renable beating from the cup during following, 1. Determine the previous bearing position by matching the wear patterns on the cup bore and the buck of the bearing. If this cannot be done, a new bearing should be installed. This see974 Section 6 is the only case where a lower main bearing may be renewed independently. determined, mark a y right or left bank 2. When previous position pocket to ident mud side, Thoroughly clean the bearing back and cap bore, Remove any raised miaterial in fretted reas. High spots may distort the hearing and Cause premature failure Thoroughly clean the cap and frame serrations before assembly. REMOVAL AND APPLICATION Lower main) bearings are to be removed with the bearing caps. and mew bearings installed in the caps before the caps are reapplied. I is recom mended practice to install new bearings with the part numbers towards the accessory end of the engine. A main bearing cap application and moval tool is avaiable for removal and applica ion of main beaving, caps All upper main bearings, except No. 5 on 8-eyline der engines, No. 7 on 12 = (\ _— we + Spring Segments With Coil Spring Section 6 Maintenance Program or at the time of a com- plete engine overhaul, The accessory drive gear requires very little maintenance, AU inspection Intervals, it should be disassembled for inspection ‘of parts, Parts which show obvious damage should be replaced, GEAR ‘The gear should be inspected for rough or scored surfaces On the gear teeth, and magnaflux inspected, IT wear in excess of maximum limit occurs on the drive side of holes, the gear should be reversed. The serial number side of the gear is phiced adjacent to the oil slinger at onginal installation, To identify the drive side when gear is reversed, the original serial number should be ground off and re-stamped on the opposite side ‘The neeximan bore diameter is permissible, pro- vided that the ub to gear clearance dos not exceed the ouiximum limit. (This bore may be chrome plated and reground to new dimension) hus. A hub having 2 7.4978" diameter may be used if the maximum hub to gear clearance is not ex- ceeded. ad oh = ie 1s Sowers NY (Hub & Disc Fig. 6-8 — Accessory Drive Gear, Exploded View (16 Cyl.) 7]Section 6 Disc The disc may be re-used providing the spring segment bores do not exceed maximum diameter and are otherwise in good condition, SPRING SEGMENTS. Spring segments should be marked, prior te dis- assembly, as to their relative position in the gear Wear should be checked on the right-hand sex- ment half (viewed at 12 o'clock position) where the segment contacts the gear bore when driving the gear. If wear at this point exceeds ntaximum Jimit, the segment half should be replaced, When reassembling spring scements, relocate the segment, originally on the driven side, to the drive side, and place the replacement segment at the driven sige of the gear. SPRINGS, Springs may be re-used providing pre-load exists AL assembly of the spring and segments inthe ear. PHOSPHATE TREATMENT IL is recommended that the gear, hub, dises, and seements be phosphate treated before reassembly. ASSEMBLY Before reassembling the drive gear, be sure all parts are clean and well lubricated. Place the slotted disc on the bench with the slots faving dowa, and apply the gear over the dise, Align the holes in the gear and disc. Place a coil spring between two sczments, and with the tabs down, and the assembly pressed together, start it into the gear, Drive the assembly atl the way down, sing a rawhide miallet, until the tabs enter the slot in the dise, Repeat this operation for the remaining spting assemblies. After they are in place, install the wab in the gear bore, and apply the top disc. Line up the dowel holes in both discs and hub, and apply tke dowels. A snug dowel fit should be maintained by teaming, and i necessary, applying oversize dowels. A bolt and nut should be used to clamp the assembly together until it is applied to a crankshaft When applying the assembly to the crankshaft, apply the oil slinger, dowel bolts, hardened wasliets, and mounting bolts. Tongue the mount: ing bolts 10 300 ft-lbs. ACCESSORY DRIVE HOUSING APPLICATION AND ALIGNMENT ‘The following proceduse is provided to properly align the accessory drive housing to the accessory drive and governor drive assemblies for sub- sequent application of the water and lube oll pumps. NOTE: File numbers in the procedures represent drawings containing the construction details for the equipment referenced. ‘These drawings are available, upon. re= quest, from ElectioMotive Servie Department. Apply sealing compound to accessory drive housing mounting flange, and apply gasket 2, Place mounting bolts and washers in housing mounting holes, 3. Using holding fixture (File 758) and a suit- able lifting device, position housing. to erank- case and secure with one mounting holt on each side Of housing. Fig, 6-9. ra0se Fig. 6-9 ~ Accessory Drive Housing Positioning 8 werers4, Remove holding fixture from housing, 5. Han tighten all mou ing bolts. 6. Apply letthand water pump alignment gauge (File 761) to teft pump opening in. housing so thet gauge gear teeth mesh with governor rive gear, Fig, 6-10. EP ingot . GG ig Sw Gouge File762 Fig, 6-10 Accessory Drive Housing Alignment 7. Apply right-hand water pump alignment gauge (File 762) to right pump opening in housing, so thut gauge gear tecth mesh with governor drive gear Apply oil pump alignment gauge (File 763) to tie main lube oil punip opening in housing so that gauge gear teeth mesh with accessory drive gear. This sme gauge is used t0 align the housing to the governor drive gear. Apply another oil pump alignment gauge (File 763) to scavenging oil pump opening in hous ing so that gauge gear teeth mesh with avees- sory drive gear, Position jacking tool (File 759) over the end of the accessory drive shaft until the “dusting nuts aren line with the accessory drive opening, Fig. 6-10. 2081273 69 It 13. 18. 19. Section 6 Movement of the vertical adjusting nuts will affect the gauge readings of the govemor drive gear and the accessory drive gear that are taken by the alignment gauge applied to the main lube oi! pump opening. Movement of the horizontal adjusting nuts will affect the gauge reading of the accessory drive gear which is taken by the alignment gauge applied to the scavenging oil pump opening. Insert spline end of jacking tool (Fite 760) into splines of the governor drive geer Mange until the adjusting nuts are in fine with the governor drive opening. Adjusting nuts should be in a horizontal position, Fig, 6-10. Movement of the adjusting nuts affects the gauge readings of the govemor drive gear which are taken by the alignment gauges ‘mounted at the water pump openings Agjust both jacking, tools until all four gauges Indivate within .008"-016" clearance between the gauge gears and the engine-mounted gears. Disengage the gear of the alignment gauge mounted ia the main lube oil pump opening from the accessory drive gear and rotate approximately 180° to mesh with the gov cmor drive gear. Recheck all gauge indications. For .008" to .016" clearance. |. Tighten four mounting bolts, preferably one ‘on each side, and one at top and bottom, Remove both jacking tools from housing, Cheek all alignment gauges. IF all indications are within ,008".016", tighten remaining housing mounting bolts to 65 ft-lbs. Ream dowel holes on sides of accessory drive housing, Fig. 6-10, to. align with holes in crankcase. This probably will not be required if the original housing and case/pan assembly are used. Insert 5/16"-24 x 2" 1/2" into dowel. x 2" bolts approximately Place dowcis in dowel holes of accessory drive housing, and drive into crankeass. Remove bolts from dowel pins.RING GEAR AND COUPLING DISC (FLYWHEEL) DESCRIPTION The ring gear. Fig. G-11, is used om engines equipped with starting motors. Engaging the teeth on the fing gear rotates the erumkshafl for engine sturling oF sclecty 3 crankshaft position when Using an engine Wuning gear device. The ring gear pilots on the engine side of Ure coupling dise and 1s bolted 10 the coupling disc The coupling dise serves as the coupling between the engine crankshatt and the driven shalt Degree and top dead center markings are stamped fom the outer rim of the coupling disc, Holes are also provided around the circumference of the tim for insertion of a turning bar to manvally rolute the crankshaft MAINTENANCE tion on the engines is the same, The serrated coupling is assembled without using body bound 610 bolts and for this reason has no reamed holes. All rim bolts are the same size. The coupling disc should be applied to the cranksha!t with the small "O" marks on the coupling dise and the crankshaft coinciding. This will position he coupling with the pointer at the 0" matk on the rim when the No. T piston is at TDC Tighten the engine coupling bolls to 3 torque value of 1800 ft-lbs. Tighten th bolts une formly (10 avoid cocking the coupling on the serrations) to a torque value of 295 ft-lbs, The gap between the coupling halves at the rim bolts should not be less than misimum after the rim bolts have been properly torqued. CAUTION: The coupling bolts must be applied with the chamfered side of the head placed adjacent to the ¢rankshatt fillet Face runout and rim concentricity. should be checked after installation of coupling dise to crankshaft, and with crankshaft positioned to avoid thrust interference. Eccentricity of rim laken at the machined groove and runovt on rim should not exce jum indicator read- n Service Dats. [Coupling Dise 16Cyi 003 Gear And Coupling Dise Installations searsAUXILIARY DRIVE COUPLING DESCRIPTION ‘The auxitiary drive coupling assembly, Fig. 6-12, js bolted and keyed to the tapered front end of the emnkshaft to provide a power takeoft con components driven from the front of nection fe the engine aca74 Section 6 MAINTENANCE The auxiliary drive coupling does not require any routine maintenance. However, replacement. of the rubber center-bonded joints may be required or desired. To. facilitate removal and replacement of the rubber joints, use a remover-installer tool. When installing the rubber joints, a small amount of rubber lubricant should be applied only on the leading pressed rubber edge of the joint, Lubri- cant should be mixed well with three to five parts water and should be stirred oveasionally while in-use The rabher joint must be installed past the normal location to properly seat the lips on the joint. The removerinstaller tool must then be reversed and the joint positioned so that the tequired dimension is obtained from the outer surface of the coupling assembly to the shoulder Of the joint. A gauge is available to measere this distance a niended before installing or utilizing the center-bonded joint num of 72 hours drying time is recom- ubber When installing the auxiliary drive coupling, the 1-1/4"-12 bolt should be tightened to a torgue of 500 ftbs, 611/612Section 6 SOUTH AFRICAN RAILWAYS SERVICE DATA CRANKSHAFT AND ACCESSORIES SPECIFICATIONS Crankshalt Diameter, main journal ~ New . 7.498"-7.500" Limit a ~ 7.4965" Diameter, crankpin journal ~ New . oe 6.498"-6.500" Liont 6.4965" Main bearing bore with all caps applied and torqued to 750 f1bs, (Take two sets of main bearing bore measurements at each bare, one set 1/2" in from the accessory end of the bore and one set 1/2 from the gencrator end of the bore. Ref. Fig, 6-3.) Diameter of bon: Max : . : 82 Min : 8.247 Clearance (diametric) ma rod bearings to erankshalt — New ee : bees : : . . .007".011" Limit bees Stee bees ols" nd connceting, Number of main bearings — loyt bees a ) The following measurements are not applicable to normal main bearing maintenance, but they should be checked when an engite hiss been torn down for reasons other than main bearing trouble. Wall thickness variation between adjacent lower main bearings hiving crankpin between them = Max... . ses. 002" Wall thickness variation between center lower main bearings with no crankpin between them = Max. 0... ose . . 001s" Main Bearing Thickness Standard ~ Min, 368" Undersize 1/32" — Min. : 3835" Undersize 1/16" = Min, : : See 3990" Thrust Bearing Clearance = New see : see . 008".018" Limit : sone : 030" Thrust Bearing Collar Thickness ee ce 5 368"369" seco74 613Section Accessory End Gear Train Backlash (atl drive years) = New . Limit : Lo Accessory Drive Gear Hub to gear clearance ~ New Max Sole : Diameter of gear spring segment holes - New Wear on drive side of gear ~ Max Gear bore diameter ~ New Max. ee . (if hub to gear maximum clearaney is not exceeded) Hub outside di (if hub to yeter — Mi, Fmaxinun el nee 6 not Cxeeeded) Disc spring segment bore - Max. Spring seament wear (right half as viewed $com 12 o'clock position) - Max. Flexible Coupling Clearance between coupling dises at Fim bolts, after bolts are torqued ~ Min Coupling face ramout (taken at machined groove) ~ Mas. Coupling rim runout ~ Max EQUIPMENT LIST Upper main bearing shell remover bene Sealing compound, gasket (I pt) 2. Thread lubricant (approx. 5 gal.) cee Main bearing cap application and removal tool Upper main bearing removal tool Sorration gauge. Accessory drive housing Holding fixture Accessory drive housing jacking fixture Accessory drive housing jacking Fixture Accessory drive housing atigning ga LH. water pump appheation Accessory drive housing, aligning gauge RH. water punip application Accessory drive housing aligning gauze ~ Oi pump application 614 008".010" 025" .0015"*.003"" 0035" 2.443" - 2.447 001" 7.500"-7,501" 7.502" 7.4975" 2.498" 001" 0015" - 010" TLR, 005" TLR Part No. 8055837 8178639 8307731 es 8487487 8488833 = 9081052 File 758 File 759 File 760 File 761 File 762 File 763 SHESTASection 6 ED 34-200 ONLY Harmonic Balancer Number of leaves per spring pack (approximate) .., Inner coupling face spring pin wear depth - Max, .. , Wear limit on end of spring pack cell (housing) - Max. -........-.4.. .050" Clearance between end of gauge bar and spring pin (center block touching springs and opposite end of bar touching spring pin) - Min, ...-.-++ 5 seeeees 010" Clearance between coupling mounting flanges - Less than ...++++.+++ 0015" Clearance between top of spring pack and coupling - Min. ... 010" 6-14A June, 1971