Preliminary Instructions Main Bearing Change Out Procedure

Note: this is for the new style main bearings (x2003091 and x2003092)

Detensioning 1. Rotate crank so that counterweights are up and will not be in the way of main bearing removal 2. Apply tensioners using tensioner cradle

3. Run both tensioners all the way down, and then back off turn so the tensioners will not bind when tension is released on studs 4. Apply jumper hose to tensioners

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5. Apply hydraulic pump hose to tensioner jumper hose

6. Apply hydraulic pump hose and 110 psi air to pump

Note: If the tensioners are not fully collapsed, seat on mains, make sure needle valve is open, and turn down using allen wrench (back off turn when finished)

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7. Close pump needle valve

8. Turn pump on until it reaches 19,000 psi, and then turn off

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9. Use tommy bar to loosen nuts at least turn

10. Open pump needed valve to remove pressure 11. Remove hoses 12. Remove tensioners using tensioner cradle 13. Remove main bearing cap nuts

Cap Dropping 1. Apply cap lifting bracket to bottom of main bearing cap

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2. Apply cap- lifting device onto crankcase. Adjustments may be necessary to align fixture to line up with cap bracket. Tighten fixture down to case. Fixture is aluminum, so do not overtighten.

3. Raise device to put pressure on the bottom of main bearing cap

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4. Remove crossbolts from both sides of cap

5. Lower cap by loosening fixture screw.

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Note: Dont lower past rounded end of fixture!

Bearing removal 1. Remove lower bearing for inspection 2. Apply upper bearing sweep tool (40080603) into oil hole of crank (may have to rotate crank to apply)

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3. Rotate crank counterclockwise (facing rear end) to sweep out upper bearing for inspection (counterclockwise because there is a tang in the bearing)

Bearing application 1. Apply a light film of oil to upper bearing 2. Apply upper bearing by hand aligning tang on bearing with tang slot on main 3. Apply oil to lower bearing 4. Apply lower bearing aligning tang on bearing with tang slot on cap

Cap Lifting 1. Make sure there is no debris on cap/ case mating surfaces

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2. Raise main bearing cap using cap-lifting device, make sure cap is aligned with dowel pin. Some wiggling may be needed to align properly.

3. 4. 5. 6. 7.

Make sure cap is seated against case Lubricate threads, heads, and washers of crossbolts with threadtex grease and apply Pre-torque right side bolt to 373 N m (275- ft. lbs.) Pre-torque left side bolt to 373 N m (275- ft. lbs.) Remove cap-lifting device

Tensioning 1. Make sure main bearing studs are tight, if not, torque to 203 Nm (150- ft. lbs.) 2. Apply and seat main bearing nuts using tommy bar, make sure drive holes are facing out 3. Apply tensioners using tensioner cradle 4. Run both tensioners all the way down and make sure rams are compressed. Note: if rams are extended too far, the seal will blow out. 5. Take out ultrasonic bolt gage 6. Clean bottom of stud 7. Apply couplant to transducer 8. Apply transducer to bottom of stud and take initial bolt length readings with ultrasonic bolt gage
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9. Apply jumper hose to tensioners 10. Apply pump hose to tensioner jumper hose 11. Close pump needle valve 12. Turn pump on until it reaches 19,500 psi, and then turn off, this correlates to a load of 267,000 lbs. 13. Use tommy bar to tighten nuts 14. Open pump needed valve to remove pressure 15. Repeat steps 8 11 one more time 16. Take final bolt stretch readings using ultrasonic bolt gage 17. Final stretch to be 0.043 to 0.0505 18. Remove hoses 19. Remove tensioners using tensioner cradle 20. Torque right side crossbolt to 1491 Nm (1100- ft. lbs.) 21. Torque left side crossbolt to 1491 Nm (1100- ft. lbs.)

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