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Technical Publication

Diesel Engine 8V 4000 G 12V 4000 G 16V 4000 G

Tolerances and Wear Limits List

M070040/00E

Printed in Germany 2002 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten.

Printed in Germany 2002 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.

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Please mark all filed amendments here.

Please use block capitals!

mark all filed amendments here. Please use block capitals! No. Date Name 1. 02-07   2.

No.

Date

Name

1.

02-07

 

2.

   

3.

   

4.

   

5.

   

6.

   

7.

   

8.

   

9.

   

10.

   

11.

   

12.

   

13.

   

14.

   

15.

   

16.

   

Receipt

Amendment No.

Publication number:

Name Manufacturer Department Fax Street Postal box number (Postal code) City Country

M070040/00E

Telephone

1.

02-07

2.

 

3.

 

4.

 

5.

 

6.

 

7.

 

8.

 

9.

 

10.

 

11.

 

12.

 

13.

 

14.

 

15.

 

16.

 

Contents

Page

1

Contents

General Information

010

Crankcase

020

Gear train

030

Running gear

040

Cylinder head

050

Valve gear

200

Coolant system

Preliminary Note

Data Sheets

Page

2

Contents

General Information

The tolerances and wear limits indicated in this publication are intended as a guide for the examination of engine components during inspection and repair.

Explanation of terms for dimensions of new components

Tol. size

Designed size followed by a letter/number symbol (e.g. 24 H6 ) or by the permissible dimensional deviation (e.g.

24

+0.013 )

Basic size

Designed size without fit symbol or quotation of dimensional deviation

Deviation

Permissible deviation from the basic or toleranced size, indicated by the upper and lower limits

Clearance

Difference between bore and shaft diameters when bore diameter is greater than shaft diameter

Interference

Difference between bore and shaft diameters when bore diameter is smaller than shaft diameter

Explanation of terms for reconditioning and operational limits

Wear limit

The limit dimensions specified do not represent the absolute maximum values permissible for satisfactory engine operation.

They indicate that the next basic overhaul can be reached safely.

If a limit value is exceeded, the component must be replaced.

Reconditioning

If values exceed or drop below limit values, the components must be reconditioned in accordance with the relevant reconditioning instructions or replaced.

instructions

Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limit values, unless exceptions are specifically indicated.

All dimensions are given in "mm", unless alternative units of measurement are specifically indicated.

Crankcase

Group

Page

010

1

Cylinder Liner

Crankcase Group Page 010 1 Cylinder Liner No.   Designation Stage Tol. size Deviation

No.

 

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

 

Basic size

lower

upper

min.

max.

min.

max.

1

Housing bore

0

196.000

H7

0

+ 0.046

 

0.059

 

0.016

 

-

upper fit

1

196.500

H7

Cylinder liner

0

196.000

j6

- 0.013

+ 0.016

-

upper fit

1

196.500

j6

2

Housing bore

0

189.000

H7

0

+ 0.046

0.050

0.125

     

-

lower fit

1

189.500

H7

Cylinder liner

0

189.000

f6

- 0.079

- 0.050

-

lower fit

1

189.500

f6

3

Bush bore

 

170.000

H7

0

+ 0.040

0.014

0.094

     

Scraper ring

 

170.000

g7

- 0.054

- 0.014

OD

 

4

Scraper ring bore

 

164.000

H8

0

+ 0.063

         

5

Bush bore

 

165.000

H7

0

+ 0.040

         

-

installed

 

6

Marking for stage

 

Reconditioning instructions:

Re 1 and 2:

In event of cavitation at upper and/or lower fit of crankcase bore:

Introduce next repair stage and install cylinder liner of corresponding stage

Re 3 and 4:

Check scraper ring OD and ID when fitted

Re 6:

Stamp markings with 6 mm high numeral punches - at stage 1 + 0.5

Group

Page

010

2

Crankcase

Crankshaft Bearing Cap

Group Page 010 2 Crankcase Crankshaft Bearing Cap No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

 

1 Bearing cap bed

 

298.000

E9

+ 0.110

+ 0.240

0.022

0.184

     

Bearing cap width

 

298.000

p6

+ 0.056

+ 0.088

 

2 Bearing cap bed

 

298.000

H7

0

+ 0.052

   

0.004

0.088

 

Bearing cap width

 

298.000

p6

+ 0.056

+ 0.088

 

3 Screw length

 

348.000

- 0.500

+ 0.500

         

Note:

Re 1:

Install bearing cap as specified and tighten screws as per tightening specification.

Crankcase

Group

Page

010

3

Crankshaft Bearing Bore

Crankcase Group Page 010 3 Crankshaft Bearing Bore Insert crankshaft bearing cap in crankcase as per

Insert crankshaft bearing cap in crankcase as per installation instructions and tighten screws as per tightening specification.

Measure main bearing bores:

- Determine diameters a, b1 and b2 each in 2 measuring planes and from the results determine the mean values of a, b1 and

b2.

- Check roundness of bores:

Possible deviations from roundness result from the mean values of a, b1 and b2 in accordance with the equation 0.5 (b1+b2)-a

Vertical ovality - a greater than 0.5 (b1+b2) - is not permissible.

Group

Page

010

4

Crankcase

Coaxiality of Crankcase Bores for Crankshaft Bearings

Coaxiality of Crankcase Bores for Crankshaft Bearings Max. permissible deviation from coaxiality New condition

Max. permissible deviation from coaxiality

New condition

Wear limit

a in each case, adjacent left and right bearings

dia. 0.040

dia. 0.050

b 8 V from crankshaft bearing 1 to 5

dia. 0.060

dia. 0.100

c 12 V from crankshaft bearing 1 to 7

dia. 0.080

dia. 0.120

d 16 V from main bearing 1 to 9

dia. 0.120

dia. 0.140

e applicable for all bearings

0.100

0.120

f applicable for all bearings

O

0.010

O

0.035

g applicable for all bearings, not concave

-

0.010

-

0.012

h applicable for all bearings

//

0.015

//

0.018

Crankcase

Group

Page

010

5

Coaxiality of Crankcase Bores for Camshaft Bearings

010 5 Coaxiality of Crankcase Bores for Camshaft Bearings Max. permissible deviation from coaxiality New condition

Max. permissible deviation from coaxiality

New condition

Wear limit

a in each case, adjacent left and right bearings

dia. 0.040

dia. 0.050

b 8 V from camshaft bearing 1 to 5

dia. 0.060

dia. 0.100

c 12 V from camshaft bearing 1 to 7

dia. 0.080

dia. 0.120

d 16 V from camshaft bearing 1 to 9

dia. 0.120

dia. 0.140

Group

Page

01

6

Crankcase

Gear Train

Group

Page

020

1

Idler Gear, Free End

Gear Train Group Page 020 1 Idler Gear, Free End No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

 

1 Equipment carrier

 

81.000

H7

0

+ 0.035

0

0.070

   

Clearance

bore

 

max. 0.080

Axle OD

 

81.000

h7

- 0.035

0

 

2 Gear bore

 

80.000

H7

0

+ 0.030

   

0.029

0.078

 

Bush OD

 

80.000

s6

+ 0.059

+ 0.078

 

3 Bush bore

                 

- installed

75.000

H8

0

+ 0.046

0.060

0.136

- removed

75.000

E6

+ 0.060

+ 0.079

Axle OD

 

75.000

e7

- 0.090

- 0.060

 

4 Equipment carrier

 

75.000

P7

- 0.051

- 0.021

0.009

0.069

   

Clearance

bore

 

max. 0.080

Axle OD

 

75.000

e7

- 0.090

- 0.060

 

5 Equipment carrier

 

41.200

0

+ 0.200

0.050

0.800

   

Clearance

width

max.

Gear width

 

40.700

- 0.100

0

0.090

 

6 Crankcase

Note:

Re 5:

Measure equipment carrier width when it is free of tension.

Group

Page

020

2

Gear Train

Running Gear

Group

Page

030

1

Crankshaft Bearing Arrangement, Free End

Page 030 1 Crankshaft Bearing Arrangement, Free End No.   Designation Stage Tol. size Deviation

No.

 

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

 

Basic size

lower

upper

min.

max.

min.

max.

1

Equipment carrier

 

193.000

H6

0

+ 0.029

   

0.175

0.233

Interference

bore

 

min. 0.150

Bearing OD

 

193.204

0

+ 0.029

-

not installed

2

Bearing bush bore

 

180.121

0

+ 0.069

0.321

0.430

   

Clearance

max. 0.450

-

bearing fitted

Driver flange OD - not press-fitted

 

179.800

h7

- 0.040

0

         

Group

Page

030

2

Running Gear

Crankshaft Seal, Free End

Page 030 2 Running Gear Crankshaft Seal, Free End No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

1

Inner star bore

 

198.000

H7

0

+ 0.046

 

0.059

 

0.016

 

Driver flange OD - not press-fitted

 

198.000

j6

- 0.013

+ 0.016

2

Seal carrier bore

 

230.000

H8

0

+ 0.072

   

0.278

0.590

 

Shaft seal OD

 

230.470

- 0.120

+ 0.120

3

Running surface

 

199.800

h9

- 0.115

0

         

OD

 

4

Radial-lip oil seal fitted flush

 

Reconditioning instructions:

Re 3:Running surface worn: Metal-spray running surface and grind using feed-in method

Running Gear

Group

Page

030

3

Crankshaft Bearing Arrangement, Alignment Bearing

030 3 Crankshaft Bearing Arrangement, Alignment Bearing No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

 

1 Housing bore

0

- 0

171.000

H6

0

+ 0.025

       

171.035

0

- 1

171.000

H6

Transverse

0

- 2

171.000

H6

ovality

0

- 3

171.000

H6

max. 0.050

1

- 0

171.500

H6

0

+ 0.025

1

- 1

171.500

H6

171.535

1

- 2

171.500

H6

Transverse

1

- 3

171.500

H6

ovality

   

max. 0.050

 

2 Alignment bearing

0

- 0

160.120

0

+ 0.054

0.120

0.199

   

Transverse

diameter

0

- 1

159.620

ovality max.

- installed

0

- 2

159.120

0.050

0

- 3

158.620

1

- 0

160.120

0

+ 0.054

1

- 1

159.620

1

- 2

159.120

1

- 3

158.620

Main bearing

0

- 0

160.000

h6

- 0.025

0

159.970

journal

0

- 1

159.500

h6

159.470

OD

0

- 2

159.000

h6

158.970

0

- 3

158.500

h6

158.470

1

- 0

160.000

h6

- 0.025

0

159.970

1

- 1

159.500

h6

159.470

1

- 2

159.000

h6

158.970

1

- 3

158.500

h6

158.470

Group

Page

030

4

Running Gear

Crankshaft Mounting, Alignment Bearing Spreading Dimension

Crankshaft Mounting, Alignment Bearing Spreading Dimension No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

1

Alignment bearing, upper half

 

2

Alignment bearing, lower half

 

3

Spreading dimension - Alignment bearing, upper and lower halves

0

- 0

171.200

0

+ 0.500

         

0

- 1

171.200

0

- 2

171.200

0

- 3

171.200

 

1

- 0

171.700

0

+ 0.500

1

- 1

171.700

1

- 2

171.700

1

- 3

171.700

Running Gear

Group

Page

030

5

Crankshaft Bearing Arrangement

Gear Group Page 030 5 Crankshaft Bearing Arrangement No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

 

1 Housing bore

0

- 0

171.000

H6

0

+ 0.025

       

171.035

0

- 1

171.000

H6

Transverse

0

- 2

171.000

H6

ovality

0

- 3

171.000

H6

max. 0.050

1

- 0

171.500

H6

0

+ 0.025

1

- 1

171.500

H6

171.535

1

- 2

171.500

H6

Transverse

1

- 3

171.500

H6

ovality max.

   

0.050

 

2 Crankshaft bearing

0

- 0

160.120

0

+ 0.054

0.120

0.199

   

Transverse

diameter

0

- 1

159.620

ovality max.

- installed

0

- 2

159.120

0.050

0

- 3

158.620

1

- 0

160.120

0

+ 0.054

1

- 1

159.620

1

- 2

159.120

1

- 3

158.620

Main bearing

0

- 0

160.000

h6

- 0.025

0

159.970

journal

0

- 1

159.500

h6

159.470

dia.

0

- 2

159.000

h6

158.970

0

- 3

158.500

h6

158.470

1

- 0

160.000

h6

- 0.025

0

159.970

1

- 1

159.500

h6

159.470

1

- 2

159.000

h6

158.970

1

- 3

158.500

h6

158.470

Group

Page

030

6

Running Gear

Crankshaft Bearing Arrangement

Page 030 6 Running Gear Crankshaft Bearing Arrangement No.   Designation Stage Tol. size Deviation

No.

 

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

 

Basic size

lower

upper

min.

max.

min.

max.

1

Main bearing, upper half

 

2

Main bearing, lower half

 

3

Spreading dimension

0

- 0

171.400

0

+ 1.000

         

0

- 1

171.400

-

Main bearing, upper and lower halves

0

- 2

171.400

0

- 3

171.400

 

1

- 0

171.900

0

+ 1.000

1

- 1

171.900

1

- 2

171.900

1

- 3

171.900

Running Gear

Group

Page

030

7

Axial Clearance - Crankshaft

Gear Group Page 030 7 Axial Clearance - Crankshaft No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

1

Axial clearance

       

0.200

0.600

   

Clearance

- crankshaft

min. 0.100

max. 0.700

2

Flywheel fitted flush

Group

Page

030

8

Running Gear

Crankshaft Seal, Driving End

Page 030 8 Running Gear Crankshaft Seal, Driving End No   Designation Stage Tol. size Clearance

No

 

Designation

Stage

Tol. size

Clearance

Interference

Wear limit

.

 

lower

upper

min.

max.

min.

max.

1

Flywheel bore

 

707.030

707.290

   

0.700

1.150

 

-

not shrink-fitted

Flywheel OD

 

673.990

708.180

2

Flywheel bore

 

673.050

673.130

 

0.065

 

0.075

 

Adapter OD

 

673.075

673.125

3

Flywheel housing bore

 

240.000

240.072

   

0.278

0.590

 

Radial-lip shaft seal OD

 

240.350

240.590

4

Running surface OD

 

209.585

209.700

         

5

Radial-lip shaft seal flush-fitted

 

6

Flywheel fitted flush

 

Reconditioning instructions:

Re 4:Running surface worn: Metal-spray running surface and grind using feed-in method

Running Gear

Group

Page

030

9

Crankshaft Bearing Shells

Gear Group Page 030 9 Crankshaft Bearing Shells Install bearing shells and tighten bearing cap according

Install bearing shells and tighten bearing cap according to tightening specifications.

Measure crankshaft bearing bores:

- Determine diameters, a, b1 and b2 in measuring planes 1 and 2 and in each case calculate mean values of a, b1 and b2.

- Check roundness of bores:

Possible deviations from roundness result from the mean values of a, b1 and b2 in accordance with the equation 0.5 (b1+b2) -a

Replace bearing shells

- If deviation from roundness 0.040

- If b1 to b2 greater than / less than 0.040

- With vertical ovality - a 0.5 (b1+b2) - is not permissible.

Group

Page

030

10

Running Gear

Counterweight Fixture

Group Page 030 10 Running Gear Counterweight Fixture No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

1

Screw length

 

130.000

- 0.400

0

       

max. length

- removed

132.000

Reconditioning instructions:

Re 1:

If wear limit has been exceeded: replace screw

Running Gear

Group

Page

030

11

Crankshaft Gear, Free End

Gear Group Page 030 11 Crankshaft Gear, Free End No.   Designation Stage Tol. size Deviation

No.

 

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

 

Basic size

lower

upper

min.

max.

min.

max.

1

Gear press-fitted

 

145.500

- 0.300

+ 0.300

         

-

Crankshaft end to gear face

Group

Page

030

12

Running Gear

Crankshaft, Coaxiality of Main Bearing Journal 8 V 4000

Gear Crankshaft, Coaxiality of Main Bearing Journal 8 V 4000 Max. permissible deviation from coaxiality New

Max. permissible deviation from coaxiality

New condition

Wear limit

From main bearing journal 1 to main bearing journal 5

0.100

 

From main bearing journal to main bearing journal

0.050

 

Note:

The crankshaft must be supported in main bearings 1 and 5.

Running Gear

Group

Page

030

13

Crankshaft, Concentricity of Main Bearing Journal 12 V 4000

Crankshaft, Concentricity of Main Bearing Journal 12 V 4000 Max. permissible deviation from coaxiality New condition

Max. permissible deviation from coaxiality

New condition

Wear limit

From main bearing journal 1 to main bearing journal 7

0.100

 

From main bearing journal to main bearing journal

0.050

 

Note:

The crankshaft must be supported in main bearings 2 and 6.

Group

Page

030

14

Running Gear

Crankshaft, Concentricity of Main Bearing Journal 16 V 4000

Crankshaft, Concentricity of Main Bearing Journal 16 V 4000 Max. permissible deviation from coaxiality New condition

Max. permissible deviation from coaxiality

New condition

Wear limit

From main bearing journal 1 to main bearing journal 9

0.100

 

From main bearing journal to main bearing journal

0.050

 

Note:

The crankshaft must be supported in main bearings 2 and 8.

Running Gear

Group

Page

030

15

Crankshaft, Dynamic Balancing 8 V 4000

Page 030 15 Crankshaft, Dynamic Balancing 8 V 4000 Balancing specification New condition Wear limit

Balancing specification

New condition

Wear limit

Max. operating speed:

1900 rpm

   

Mass of balancing group:

463 kg

The crankshaft must be supported in main bearings 1 and 5.

Balancing speed:

150 rpm

Permissible residual imbalance for each balancing plane during initial balancing:

135

gcm

Permissible residual imbalance for each balancing plane for comparable balancing in other clamping or balancing machinery

400

gcm

Reconditioning instructions:

It will only be necessary to rebalance the crankshaft if the counterweights have been replaced.

If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweights have not been replaced.

Mark the counterweights and reassemble them according to marking.

Group

Page

030

16

Running Gear

Crankshaft, Dynamic Balancing 12 V 4000

16 Running Gear Crankshaft, Dynamic Balancing 12 V 4000 Balancing specification New condition Wear limit

Balancing specification

New condition

Wear limit

Max. operating speed:

2100

rpm

   

Mass of balancing group:

525

kg

The crankshaft must be supported in main bearings 2 and 6.

Balancing speed:

150

rpm

Permissible residual imbalance for each balancing plane during initial balancing:

200

gcm

Permissible residual imbalance for each balancing plane for comparable balancing in other clamping or balancing machinery

600

gcm

Reconditioning instructions:

It will only be necessary to rebalance the crankshaft if the counterweights have been replaced.

If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweights have not been replaced.

Mark the counterweights and reassemble them according to marking.

Running Gear

Group

Page

030

17

Crankshaft, Dynamic Balancing 16 V 4000

Page 030 17 Crankshaft, Dynamic Balancing 16 V 4000 Balancing specification New condition Wear limit

Balancing specification

New condition

Wear limit

Max. operating speed:

1800

rpm

   

Mass of balancing group:

710

kg

The crankshaft must be supported in main bearings 2 and 8.

Balancing speed:

150

rpm

Permissible residual imbalance for each balancing plane during initial balancing:

200

gcm

Permissible residual imbalance for each balancing plane for comparable balancing in other clamping or balancing machinery

300

gcm

Reconditioning instructions:

It will only be necessary to rebalance the crankshaft if the counterweights have been replaced.

If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweights have not been replaced.

Mark the counterweights and reassemble them according to marking.

Group

Page

030

18

Running Gear

Conrod Bearing

Group Page 030 18 Running Gear Conrod Bearing No.   Designation Stage Tol. size Deviation

No.

 

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

 

Basic size

lower

upper

min.

max.

min.

max.

1

Conrod bore

 

126.000

H6

0

+ 0.025

         

2

Conrod bearing

0

- 0

117.082

0

+ 0.048

0.082

0.152

     

bore

0

- 1

116.882

-

Conrod bearing

0

- 2

116.682

installed

0

- 3

116.482

Crankpin journal

0

- 0

117.000

h6

- 0.022

0

dia.

0

- 1

116.800

h6

0

- 2

116.600

h6

0

- 3

116.400

h6

3

Crankpin length

 

97.500

- 0.100

+ 0.100

0.200

0.600

     

Conrod width

 

48.600

- 0.100

0

4

Spreading dimension

0

- 0

126.400

0

+ 1.000

         

0

- 1

126.400

-

Conrod bearing shell, upper and lower halves

0

- 2

126.400

0

- 3

126.400

Running Gear

Group

Page

030

19

Conrod Bearing, Locating Pin

Gear Group Page 030 19 Conrod Bearing, Locating Pin No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

1

Locating pin bore

 

7.000

H7

0

+ 0.015

   

0.004

0.028

 
 

Locating pin OD

 

7.000

r6

+ 0.019

+ 0.028

         

Group

Page

030

20

Running Gear

Conrod Bearing Bore

Group Page 030 20 Running Gear Conrod Bearing Bore No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

1

Screw length

 

103.000

- 0.400

+ 0.200

       

104.500

- removed

Note:

Tighten conrod - conrod cap as per tightening specifications.

Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a.

Re 1:

If wear limit has been exceeded: replace screw

Running Gear

Group

Page

030

21

Conrod Bearing Shells

Running Gear Group Page 030 21 Conrod Bearing Shells No. Designation Stage Tol. size Deviation

No.

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

Basic size

lower

upper

min.

max.

min.

max.

1

Screw length

 

103.000

- 0.400

+ 0.200

       

104.500

- removed

Note:

Tighten conrod bearing - conrod - conrod cap as per tightening specifications.

Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a.

Re 1:

If wear limit has been exceeded: replace screw

Group

Page

030

22

Running Gear

Parallellity of Conrod Bores

Page 030 22 Running Gear Parallellity of Conrod Bores No.   Designation Stage Tol. size Deviation

No.

 

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

 

Basic size

lower

upper

min.

max.

min.

max.

1

Conrod length

 

354.000

- 0.100

+ 0.100

         

-

with bush and without bearing shells

Conrod length

 

354.000

- 0.100

+ 0.100

 

-

without bush and without bearing shells

2

Parallellity of axles

0.070

measured at 100 mm distance

 

Inclination

 

max. 0.100

-

Inclination

3

Parallellity of axles

0.250

measured at 100 mm distance

 

Twist max.

 

0.350

-

twist

Conrod weight

9.530

kg

- 0.060 kg

+ 0.060 kg

   

Running Gear

Group

Page

030

23

Piston Bearing

Running Gear Group Page 030 23 Piston Bearing No.   Designation Stage Tol. size Deviation

No.

 

Designation

Stage

Tol. size

Deviation

Clearance

Interference

Wear limit

 

Basic size

lower

upper

min.

max.

min.

max.

1

Conrod bore

0

75.000

H6

0

+ 0.019

   

0.101

0.139

Axial test

1

75.200

H6

load for

2

75.400

H6

bush

installed

Bush OD

0

75.000

v6

+ 0.120

+ 0.139

min.

1

75.200

v6

17000 N

2

75.400

v6

2

Bush ID

 

68.000

+ 0.070

+ 0.080

0.070

0.085

   

Clearance

-

finished-

max. 0.090

machined

Piston pin OD

 

68.000

- 0.005

0

3

Bush ID

 

68.000

+ 0.008

+ 0.018

0.008

0.023

   

Clearance

-

finished-

max. 0.025

machined

Piston pin OD

 

68.000

- 0.005

0

4

MTU part number and stage stamped on

 

Reconditioning instructions:

Re 1:

Bush loose at 17000 N test load: replace bush and introduce next repair stage if necessary.

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