F3L/F6L 912 DIESEL ENGINE SPECIFICATIONS & REPAIR PROCEDURE Section 4. Crankshaft, Camshaft, And Crankcase Caterpillar

If there are signs of wear on the bearing shells, the line of bearing housings can be reworked to an oversize outside diameter on a line boring machine. It is not permissible to bore out individual bearing pedestals. Refer to Technical Circulars.

Checking The Preload

4-1

4. Fit crankshaft bearing caps, observing the numbering, into the crankcase. Preload and tighten bolts according to instructions.

(Fixture No. 101900)

Fig. 4-1

4-2

5. Set precision gauge to the size indicated in the Technical Data, using a micrometer frame (nominal or oversize).

Fig. 4-2

4-3

6. Measure each main bearing bore at the points 1 and 2 in plane "a", then in the same manner in plane "b" offset by 90 degrees, see also Fig. 4-6, in order to determine any contraction, out-of-roundness or conicity.

Fig. 4-3

7. If the recorded values correspond to those specified in the Technical Data, the respective bearing bore is in acceptable condition and the required preload will be obtained when new bearing shells are installed.

4-4

8. If the recorded bearing bore diameters differ only slightly from the specified values, repeat the measurements with the new bearing shells installed.

Fig. 4-4

9. Insert new bearing shells, mount bearing cap, then preload and tighten up according to instructions.

4-5

4-6

10. Gauge each bore at points 1 and 2 in the vertical and horizontal positions "a" and "b".

Fig. 4-5 and 4-6

11. If the recordings show that the bearing tolerances are up to 0.020 mm max. above the values specified in the Technical Data, the crankcase is acceptable for further use. Otherwise, it is necessary for the line of bearing housings to be reworked to an oversize outside diameter on a line boring machine. It is not permissible to bore out individual bearing pedestals. Refer to Technical Circulars. Nor is it permissible to restore the required preload by underlaying the bearing shells or by reworking the parting faces of the bearing bores.

NOTE:

a) The main bearing shells are made in two halves and supplied in six dimensions, corresponding to the specified undersizes of the journals. No attempt may be made to recondition the shells.

4-7

b) Standard and oversize wall thickness "W" should be taken from the specifications.

Fig. 4-7

4-8

12. Measure width of locating bearing journal of the crankshaft.

Fig. 4-8

4-9

13. Assemble the thrust rings on the locating main bearing and calliper the overall width.

Fig. 4-9

14. Measure end clearance. Compare with the values given in the specifications. If necessary, fit new stop rings.

Replacing Bearing Bushing (F2L)

4-10

15. Remove the radial seal ring from the back end shield.

Fig. 4-10

4-11

16. If the main bearing journal has not been re-ground and the bearing bushing shows no signs of damage or wear, gauge the bearing bore at two diagonal points.

Fig. 4-11

17. Compare measured values with the Specification Data. If necessary, fit new bearing bushing.

4-12

18. Draw the bearing bushing in flush, with its oilholes in register with those in the housing.

Fig. 4-12

19. Fit a new radial sealing ring in the back end shield with the sealing lip facing the bearing bushing and press in so that the back face is flush.

Checking Alignment Of Bearings And Crankshaft (As From 3 Cylinders)

20. Coat the main crankshaft journals lightly with inking-in paint.

4-13

4-14

21. Place crankshaft in position, Fig. 4-13 and fit bearing caps according to the numbering. Tighten and lock down the bolts according to instructions.

Fig. 4-14

22. Turn crankshaft slowly several times, without axial displacement and without lifting it.

23. Remove crankshaft and check contact pattern of bearing shells.

Note for installation:

Proper alignment of the bearings can only be obtained if all bearings have uniform contact pattern.

24. If signs of alignment errors are noticeable, repeat the test. The line of bearing housings in the crankcase can be reworked to an oversize outside diameter on a line boring machine. It is not permissible to bore out individual bearing pedestals. Refer to Technical Circulars.

4-15

25. Check all cylinder seating areas, Fig. 4-15, for defects or damages. The seating areas must be plane and square.

4-16

26. In case of damage reface the cylinder seating areas on the crankcase with special tool No. 150020.

Fig. 4-16

4-17

27. Clean all the tapped holes by running down a top. A greased tap should be used for blind holes.

Fig. 4-17

4-18

28. Check core hole plug cover for snug fit, replace untight or loose core hole plug covers. Coat new cover with sealing compound, then drive in.

Fig. 4-18

4-19

29. Check the main bearing bores of the camshaft for damage and visible wear.

Fig. 4-19

Reworking Cylinder Seating On Crankcase

4-20

1. Clean the seating area and remove paint residues. Place supporting brackets in position.

Fig. 4-20

4-21

2. Mount refacing device No. 150020 and tighten retaining bolts to such an extent that the refacing device is still movable.

Fig. 4-21

4-22

3. Center refacing device by means of the centering fingers (arrows) and fasten.

Fig. 4-22

4-23

4. Withdraw centering fingers and slide the cutting tool holder out to just above the beginning of the inner diameter of the cylinder seating face to be reworked.

Fig. 4-23

4-24

5. By means of the knurled nut, bring the tool holder down towards the face to be reworked until the cutter just contacts the face.

Fig. 4-24

NOTE: Adjust feed carefully. A full turn (360°) of the knurled nut feeds the tool holder by 1,5 mm.

4-25

6. Turn back the knurled nut until the cutter is positioned freely above the face to be reworked. Distance "a"

Fig. 4-25

4-26

7. Return tool holder towards the middle of the bore.

Fig. 4-26

8. By means of the knurled nut, set the tool over and slightly beyond the distance "a" (Point 6) to permit satisfactory refacing of the cylinder seating surface.

NOTE: The selected cutting depth should not exceed 0,2 mm. This feed corresponds to a 1/8th turn (45°) of the knurled nut. The smaller the feed, the smaller will be the depth of roughness of the reworked surface.

4-27

9. After adjusting, secure the device by means of the setscrew.

Fig. 4-27

4-28

10. Turn spindle of device clockwise to reface the cylinder seating.

Fig. 4-28

NOTE: Feed is automatic when turning the spindle clockwise.

Remove only so much material as is necessary for obtaining a satisfactory sealing surface.

11. Loosen the setscrew and, by means of the knurled nut, raise the cutter from the reworked surface prior to removing the device.

4-29

12. After refacing the cylinder seating, clean the crankcase. The seating surface must be plane and free from grooves.

Fig. 4-29

Oil Nozzles

4-30

1. Install new oil nozzle in tool No. 151100 as shown (side with long slot), the dowel pin pointing toward the cylinder head (arrow).

Fig. 4-30

4-31

2. Install oil nozzle properly located (arrow).

Fig. 4-31

NOTE: Before installation fill annular groove with sealant.

Hole diameter on:

F4L 912 = 0,8 mm

F4/6L 913 and BF6L913 = 1,5 mm

See Technical Circular.

When installing the nozzle in the crankcase, take care that the dowel pin just comes into contact with the crankcase.

Checking And Replacing The Camshaft And Bearings

1. Check the camshaft and its gearwheel for damage and visible signs of wear.

4-32

2. Measure the journal at the drive end of the camshaft.

Fig. 4-32

NOTE: The diameter of the journal must not be smaller than the low limit given in the specifications. Renew the camshaft if it is defective.

3. Inspect the bearing bushing on the camshaft for damage and visible signs of wear.

4-33

4. With the aid of a micrometer set the internal dial indicator set to the normal inside diameter of the camshaft bearing bushing.

Fig. 4-33

4-34

4-35

5. Measure bearing bore at points 1 and 2 in the planes "a" and "b".

Fig. 4-34 and 4-35

Check for any constriction, ovalization and conicity.

4-36

6. To replace the bearing bushing place the special tool on the front end. (Use removing and replacing tool No. 143630)

Fig. 4-36

NOTE: Apply large-diameter thrust pieces if the engine is of the F2L 912 Type. As from 3 cylinder engine apply small-diameter thrust pieces.

4-37

7. Position end support of the device at the next camshaft bore (arrow). Pull bearing bushing out towards the flywheel end.

Fig. 4-37 (as from 3-cyl. engines)

4-39

8. Position new bearing bushing making sure that the oil holes in the bushing coincide with those in the crankcase.

Fig. 4-39

4-40

9. Press in the bearing bushing from the front side, without permitting it to get out of square. (Use removing and replacing tool No. 143630)

Fig. 4-40

4-42

NOTE: Press in the bearing bushing so that it seats flush with the front end.

Fig. 4-42 (As from 3 cylinder engine)

Dismantling And Installing The Camshaft (as from 3 cylinder engine)

Fasten engine in rotatable engine stand.

Dismantling

4-56

1. Remove the rocker chamber covers and the rocker brackets. Take out the push-rods. Remove cooling blower, crankcase breather tube, oil pan and oil suction pipe with strainer.

Fig. 4-56

4-57

2. Remove V-belt pulley and front cover. (Retainer for V-belt pulley No. 143400)

Fig. 4-57

NOTE: The V-belt pulley bolt has left-hand thread.

4-58

3. Remove oil pipe with oil pump. Take off idler gear with hub.

Fig. 4-58

4-59

4. Pull out camshaft.

Fig. 4-59

Installing

1. Position the gearwheels with the marks lines up and carefully insert the camshaft with gear. Note that the marking on the injection pump gear differs, depending on the number of engine cylinder (3 cylinders, or 4, 5, 6 cylinders.)

4-60

a) F3L: The reference mark on the injection pump gearwheel of this model is a figure 3 with a dot above it.

Fig. 4-60

4-61

b) F4/5/6L: Engines of these types have a dot to mark the mating point of the injection pump gearwheel.

Fig. 4-61

NOTE: Pay attention to modified marks on camshaft and injection pump gears.

2. Fit a new rubber O-seal on the discharge pipe of the oil pump.

3. Position the oil pump and pipe on the crankcase and tighten the oil pump screws. Adjust the gear flank clearance to the value stated in the specifications.

NOTE: The manufacturing material and tightening torque for the bolts fastening the lube oil pump have been changed.

4-62

4. Tighten and lock down the stud securing the idler gear mounting (on the oil delivery pipe clip), in accordance with the instructions for tightening bolts and studs.

Fig. 4-62

4-63

5. Fit oil suction pipe with strainer.

Fig. 4-63

4-64

6. Place compression spring and cap on camshaft spigot.

Fig. 4-64

4-65

7. Fit a new gasket to the front cover, strick it in position with grease and mount the cover.

Fig. 4-65

4-66

8. Grease the lip of the radial packing ring in the front cover and the contact surface of the vee-belt pulley. Install the vee-belt pulley, having brought the locating pin in the crankshaft gearwheel.

Fig. 4-66

4-67

9. Screw in bolt (left-hand thread), preload and tighten as per instructions. (Retainer for V-belt pulley No. 143400, gauge No. 101910).

Fig. 4-67

10. Apply grease to a new gasket and stick it in position on the sump. Assemble the sump.

NOTE: Tightening torque for the oil drain plugs illustrated is: 150 Nm

4-68

11. Fasten retainer for crankcase breather pipe at oil pan.

Fig. 4-68

12. Assemble the push-rods.

4-69

13. Mount the rocker brackets. Tighten nuts as quoted in Specification Data.

Fig. 4-69

4-70

14. Adjust the valve clearance.

Fig. 4-70

15. Stick new gasket with sealing compound to rocker chamber cover. Position cover, align and fit bolt with new washer. Tightening see Specification Data.

4-71

16. Align blower to holes and attach to front-end cover.

Fig. 4-71

17. Push idler pulley upward and install belt.

18. Hook in the air cowling at the top and close at the bottom.

Checking And Gauging The Crankshaft

1. Inspect crankshaft for cracks (by magnaflux method).

2. Remove the gearwheel from the crankshaft.

3. Support crankshaft at outer main journals on prism-shaped blocks.

4-72

4. Determine the hardness of the journal surfaces with a scleroscope. Conversions of the redlings to Rockwell "C" hardness values, for comparison with the specifications, can be effected with the table included with the instrument.

Fig. 4-72

5. Compare the readings with the specifications.

4-73

4-74

6. Measure all journals at points "1" and "2", in the vertical and horizontal, as indicated by "a" and "b"

Fig. 4-73 and 4-74

NOTE: Width "3" should also be measured of the journal for a locating bearing.

Fig. 4-74

7. Note the measurements on the inspection record sheets and compare with the specifications.

NOTE: Maximum permissible deviations from roundness, straightness, true run and parallelism of all shaft journals and crankpins, also adjacent ones, see drawings. Wear limit for ovality is 0,02mm.

4-75

8. With a dial indicator, check the other journals for out-of-truth.

Fig. 4-75

9. Check the working surface of the radial packing ring on the flywheel flange.

10. Recondition or renew the crankshaft if it is defective.

NOTE: If the crankshaft is to be reconditioned, first remove the oil-duct plugs and later renew same.

4-76

I = CrankpinII = Main bearing journalKs = Main bearing boreKz = Diameter of main bearing journalLs = Width of main bearingLz = Length of journalLu = Thickness of thrust washer (locating bearing)W = Radial clearance of main bearingZ = End clearance of main bearingr = Radius of journal filletsPs = Big-end bearing borePz = Diameter of crankpinBs = Width of connecting roBz = Length of crankpinX = Radial clearance of big-end bearingY = End clearance of big-end bearingR = Radius of crankpin fillets

Fig. 4-77

Machining The Crankshaft

Fig. 4-76 and list Fig. 4-77

Important:

Before machining shaft, check that no cracks are present (see 1. on previous page).

Grinding the crankshaft:

4-78

Remove balance weights (Fig. 4-78) as marked. Grind shaft journals and pins according to previous data sheet. Be sure the dimensions obtained strictly conform to Specification Data and data sheet.

WHEN MACHINING DEUTZ CRANKSHAFTS THE FOLLOWING POINTS SHALL BE STRICTLY OBSERVED:

1. Round out the oil holes free from scores and notches, do not spot-face by any means.

2. Centering pins for flywheel, vibrations dampers etc. may not be machined.

3. Make sure that width of grinding wheels used will not involve machining of web thrust faces. Instead, perfect fillets should be formed. Only high spots on thrust faces may be removed. It should be borne in mind that use is made of flangeless big-end bearings, the connecting rod - not available in oversizes - having to keep smooth contact with the thrust faces. Machining is permissible only of the thrust face of the journal with stop rings, which are available in oversizes.

Hardening the crankshaft:

Whether flame or induction hardening is applied, in no case must the hardening zone extend into the fillet.

4-79

1 = Width of hardening zone2 = Depth of hardening zoner = Fillet radius

Fig. 4-79

4. Fit counterweights in place on crankshaft carefully observing the identification marks. Tighten and tighten down screws in accordance with the instructions for tightening studs and bolts. (See Technical Data).