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100
*Rev. B
INTENANCE
ilNTRODUCTlON
The purpose of this maintenance instruction is to define the dimensions
and limits which control the size, shape, and alignment of the 567 and
645 crankcase main bearing bores. The text of the instruction is divided
into four main sections as follows:
I REQUALIFY
COMPONENTS
I
MAJOR
I
II
NOTE
REF.
MAIN
INSP.
BRG
BOOK
CONDITION -
1I
FAIL I - --- - _ _-----_
REQUIRED -1
------a-----_-
1
REAPPLY MAIN r A. 11 -t 5 MILS STUD STRETCH1
BRG CAPS --1
, -------------
B. 25 + 5 MILS STUD STRETCH-;
I
I
---------e---w--_ -_
,
-----m--e--
22252
M.I. 100
PROCEDURE
SECTION I
DETERMINING IF LINE BORE
IS REQUIRED
Obvious failures involving the main bearing/
18302
crankshaft system will require complete disassem-
bly of the engine and in almost all cases will also
require line bore. However, those engines which Fig. 1 - Main Bearing Bore Measurement
have been taken out of service for reasons other
than an obvious failure of this system can have
SECTION II
the main bearing steel bore alignment requalified
with a minimal amount of work. PREPARATION FOR LINE BORE
The condition of lower main bearings removed
from a “running” engine will provide the infor- A. QUALIFICATION OF MAIN BEARING
mation necessary to determine whether or not NUT TORQUE APPLICATION
steel bore alignment requires qualification. Bear-
ings that exhibit wear-exposed bronze in excess Stud stretch measurements should be used as the
of l/8” wide running along either edge of any criteria for monitoring torques. The objective of
one main bearing will require complete engine measuring stud stretch is to determine the actual
disassembly to facilitate crankshaft removal. clamp load of the stud/nut system and thus
ensure that the torquing method is effective. Stud
Bearings found in good condition should be stretch is defined as the overall length change of
replaced with new and will thus allow the engine the stud evaluated as the length when torqued
to be placed back into active service. minus the length after the applied torque is
removed. Measurement should be as follows:
NOTE: For further information on evaluating
main bearings, refer to “Inspection and Using a 16-inch micrometer or Vernier caliper,
Qualification of Engine Main Bearings” measure the length of the stud, being careful not
guide I book published by the Service to locate on the small projections found on the
Department of the Electra-Motive ends of each stud. The preferred method is to
Division of General Motors. hold the measuring instrument against the back
end of the stud with one hand in such a manner
As noted above, an engine which has experienced that one finger touches the stud end and locates
an obvious failure of the main bearing/crankshaft the point of measurement at approximately 3/8”
system, or has bearings which exhibit exposed radially from the side of the stud. The outboard
bronze in excess of the amount indicated above, end measurement point can be visually located in
should be disassembled to facilitate crankshaft line with the inboard end point. Operator ability
removal and the following performed. to use this method, or any other selected
method, should be checked by taking repetitive
PRELIMINARY INSPECTION -- STEEL readings. Note, that in order for these readings to
BORE DIAMETER MEASUREMENTS agree, they must be taken in the same location
on the stud ends to minimize errors due to
With the engine disassembled and the crankshaft
tapered ends.
and main bearings removed, reapply the main
bearing caps as indicated in Section II, Item C-4.
Measure the steel bore diameters as shown in Fig. The method of torque application substantially
1, using bore gauge 8275258 with master affects stud stretch. A qualified air or hydrau-
932 1276. Two sets of readings are required per lically operated wrench is recommended for main
each main frame member (MFM) taken l/2” in bearing nut application. Hand torque application
from each side (accessory and generator ends of of main bearing nuts may not be reliable and can
each MFM). The crankcase may be reused with- be expected to give a stud stretch range as high
out bore remachining if all of the diameter as .016”.
readings are within the limits provided in the
appendix, Table 1. If the crankcase does not To qualify any main bearing nut torque applica-
meet the limits provided, proceed to Section II. tion system. perform the following:
M.J. 100
Crankcases which require line bore must have the .0017” - measured perpendicular to nominal
main bearing caps reworked to obtain machining flank surface.
stock and to upgrade the serration quality.
Rework is to be as follows: The projected outline of the tooth serration
must fall entirely between two 30” lines
1. A minimum of .040” must be cut off the which are .0034” apart. See (B), Fig. 3.
crest of the senations during remachining to
ensure adequate cleanup. C. APPls,ICAT\ON OF MA\N
BEARING CAP AT LINE BORE
2. Cut the nut seat surface to remove any NOTE: Stud stretch measurements cannot be
superficial discontinuities. The nut seat sur- made on type “567B” or earlier crank-
face should be parallel to the serration pitch
line to within .OlO”. cases. Equivalent hand torques must be
used.
SERRATION SPECLFICATIONS I. Apply main bearing cap for pre-crush and line
bore using flat plate 8488128 against cap (do
NOTE: Serrations should be machined on equip- not use flat plates on “567B” and earlier
ment that has been checked to the speci- crankcases), followed by hardened washer
fications listed below. Checking should be 8412532 and nut 8408684. Apply Texaco
done by cutting senations on a sample Threadtex Lubricant 830773 1 liberally to
piece of metal (coupon) and placing it on stud threads, nut face, and both sides of the
a shadow graph (comparator) or similar washer.
machine.
2. Tighten all nuts for pre-crush as follows:
1. Serration Spacing.
a. Tighten all nuts to produce 11 + 5 mils
Measurement from the centerline of No. 2 stud stretch (350 ft-lbs Ref.).
serration on one bank to the centerline of the
No. 2 serration on the opposite bank must be b. Tighten all nuts to produce 35 Ir 6 mils
9.500” 4 .OlO”. Use gauge 9081052, Fig. 2, stud stretch (I IO0 ft-lbs Ref. 1850 ft-lbs
to determine this dimension. for “567B” and earlier crankcases] ).
-4
M.I. 100
t
.1406 +, .0050”
Flank
L! Gauge Line
(A) (B)
22253
c. Measure and record length of the above a. Apply torque to produce 11 + 5 mils
four selected studs. stud stretch (350 ft-lbs Ref.).
22254
Fig. 4 - Crankcase Supported On Precision
Granite Table
-6
M.I. 100
independent sets of dial indicator readings. Any example sheet provided is for a 16 cylinder
discrepancies between individual readings which crankcase.
are in excess of .0005” must be resolved. Record
the final corrected readings on the computation 2. Columns B and C are case line dial indicator
worksheet for Granite Table Inspection (sample readings taken at the accessory and generator
provided in the Appendix Section), end respectively of each main bearing bore.
The following sign convention must be used:
Before mathematically computing the alignment Towards topdeck is pos. (+), away from top-
functions on the worksheet it is very important deck is neg. q-j.
to understand each of the functions from a
physical standpoint. The following definitions are
provided along with an appropriate figure to NOTE: Dial indicator readings are recorded as
explain each alignment concept. positive (+) when gauge travel is towards
the topdeck and negative (-) when gauge
1. Case Line - travel is away from the topdeck. Because
The relative vertical position of the crank- of the inverted position of the gauge dial
case portion of the main bearing bores, indicator, plus (+) gauge readings are
Fig. 6. recorded as minus values.
2. Cap Line --
The relative vertical position of the main 3. Column D is the average ordinate for case line
bearing cap portion of the main bearing for each main bearing bore. This is found by
bores, Fig. 6. calculating the average of column B and C, or
[Act. + Gen.l/2 = AVG.
3. Vertical Bow - Example: [(-2.5) + (-1.2)] /2 = -1.8 mils.
The maximum deviation of the center of
any one main bearing bore from a line 4. Column E is the STEP between two adjacent
drawn through the centers of the gener- main bearing bore averages. Step is calculated
ator and accessory end main bearing bores algebraically to determine sign convention
is the crankcase vertical bow. The 16 using the following equation :
cylinder crankcase shown in Fig. 7 has a Y, - Y, = Step 1,2 Y, - Y2 = Step 2,3 etc.
maximum bow of -.003” or -3 mils sag. Example: (-1.5) - (-1,8) = +0.3,
Positive bow is referred to as crown. (-0.3) - (-1 S) = +I .2 etc.
4. Step/Effective Step - 5. Column F is a constant factor used to adjust
The difference in vertical position be- step when the span between main bearing
tween two adjacent main bearing bores bores is not 16.625” for the purpose of
(case or cap line), Fig. 8. calculating EFFECTIVE STEP. This is only
necessary on 16 and 20 cyl. engines because
5. Slope Change - the span distance between the two center
The relative vertical position of two adja- main frames is l/2 the distance between any
cent effective steps (case or cap line), two intermediate main frames, therefore, the
Figs. 9 and 10. factor is 2.
6. Case And Cap Tilt -- 6. Column G is the effective step which is the
The difference between the accessory and product (x’s) of Column E and its corre-
generator positions of any one main bear- sponding factor in Column F.
ing bore, Fig. 11.
7. Column H is the case line SLOPE CHANGE
An explanation on how to use the computation or the algebraic difference between two adja-
worksheet (for use with the granite table) fol- cent effective steps (Column G).
lows. A master worksheet, as well as a completed Example : x2 - x1 or (+1.2) (+0.3) = +0.9,
example sheet is provided in the Appendix (t-0.6) -(+I .2) = 0.6 etc.
Section.
8. Column I is the algebraic difference between
NOTE: For ease in calculating data, record as the case line readings at the generator end
mils; where .OOl” equals 1 .O mil. (Column C) and the case line readings at the
accessory end (Column B) which equals case
1. Column A indicates the main bearing position line tilt (per gauge length), or Z, - ZA or
number for 16 and 20 cylinder engines. The (-1.2)-(-2.5) = +1.3.
-7.
MA. 100
i I
I
i
I I
I 1
I I
-8-
M.I. 100
I
I I
I
I
I
1 i
t Gen 4CC.
End
I
Sign Convention
End fnd
or or
or
Step E = -1.7
+2.0 - (+0.3) = +1.7
GRANITE TA 22257
,,, ,,
THE SLOPE CHANGE IS THE RELATIVE VERTICAL POSITION
OF TWO ADJACENT EFFECTIVE STEPS.
Sign Convention
+ Towards Top
Syp i -0.004”
Step
3
2
-0.004”
7
I
I
Example: *Case Line /
Slope Change = ,
I
Case Line Step i -
I
2 I
Case Line Step 3 /
or
or
SC, = 0
Not To Scale. Line Bore
Conditions Shown Are Slope Change @ #4 = 0
For Illustrative Purposes
Only. GRANITE TABLE
L
Slope Change @ #4
I
-I
Sign Convention
L --_----- + Towards Top
Deck (See Pg. 7)
I
Step 5 -0.004”
I I
0.008”
I Step g +0.004”
*Case Line
Slope Change
SC4 =
+4.0-t-4.0) =
22259
Fig. 10 - Slope Change Vs. Step (8 Mils Change Illustrated)
Case Tilt = \ kc.
Case Line Data, Gen. - Gen. Sign Convention Ind
Case Line Data, Act. End t Towards TOP
or Deck (See Pg. 7)
ZG-ZA or
3.6 -3.4 = +0.2
Cap Tilt =
Case Tilt + *Steel Bore Diff.
Zero Reading At
Accessory End Of
No. 1 Main Bearing
Bore
-_--0
t
Cap Tilt = -0.4
+3.6
z
Fig. 11 - Case And Cap Tilt 0
M.I. 100
9. Columns J and K are vertical recap steel bore B. GRANITE MEASURING BAR METHOD
variations from the nominal bore diameter of
8.2500”, taken at the accessory end and NOTE: This procedure should only be used to
generator end respectively. The following sign determine steel bore alignment when a
convention is used: pas.(+) = Larger than precision granite table is not available.
nominal and neg.(-) = Smaller than nominal.
Example : A vertical steel bore dia. of The granite measuring bar 8467738 and gauge
8.251 I” is expressed +l.l mils; 8.2488” is assembly 8467737 are used to determine cap line
-1.2 mils. data, after the recap operation has determined
that the steel bore diameters are within accept-
10. Column L is the steel bore difference, which able limits. The bar, Fig. 12, consists of a 42”
is the accessory end steel bore size minus the long piece of polished granite with a square cross
generator end steel bore size. section and a fluid level attached to one end. The
level is used to establish horizontal attitude trans-
Example: (+l. 1) - (+1.3) =-0.2.
versely in the bore. The bar is supported by three
11. Column M is the CAP TILT per gauge length. pairs of ball-head legs spaced in such a manner
It is equal to the algebraic sum of Columns I that only two pairs of legs are in use per each
and L or case line tilt plus steel bore differ- run (the span distance between the center MFM’s
ence. Example: (+1.3) + (-0.2) = +l.l. is one half the distance between intermediates
and thus requires an additional set of legs).
12. Columns N and 0 are the cap line calcula- The gauge assembly consists of a standard clock-
tions for the accessory end and generator end wise dial type instrument with an automatic
respectively. Jt is the algebraic difference revolution counter. The numerical values obtained
between the case line dial indicator readings in this bore alignement check are merely relative;
and the steel bore variation from nominal; or meaning that there is no prior setting of the
Column B - Column J = Column N etc. and gauge in a master fixture. Gauge travel adjust-
Column C - Column K = Column 0 etc. ments are not necessary as this has been pre-
Example: (-2.5) - (+l. I) = -3.6 and established in the design make-up of the bar and
(-1.2) - (+I .3) = -2.5 etc. gauge assembly. Close attention must be paid,
however. to the number of sweeDs the nointer
13. Column P is the average ordinate for cap line 1
-14-
M.I. 100
bores, the bar is then moved to the next adjacent follows. A master worksheet, as well as a com-
MFM and leveled; meaning that the bar should pleted example are provided in the Appendix.
now span MFM’s 2, 3, and 4. This will provide
NOTE: For ease in calculating data, record as
the second run of readings (starting at the acces-
mils; where .OOl” equals 1 .O mil.
sory end of the No. 2 MFM), and this sequence is
followed through the remaining bores of the 1. Column A indicates run numbers for. 16 or 20
crankcase. The readings obtained are recorded on cylinder crankcases. Each run number deter-
the computation worksheet (for measuring bar) mines the location of the measuring bar
provided in the Appendix. within the crankcase.
NOTE: It is vitally important that at least two 2. Column B is the main bearing position
truly independent sets of readings are numbers for a 16 and 20 cylinder crankcase
taken per crankcase with the measuring per run.
bar method to insure repeatable, and thus
accurate, results. Of the two sets of 3. Columns C and D are the CAP LINE dial
readings, any discrepancies between indi- indicator readings for the accessory and gener-
vidual readings which are in excess of ator ends respectively.
.0005” (.5 mils) must be resolved.
4. Column E is the average ordinate for each
An explanation on how to use the computation main bearing bore. This is found by calcu-
worksheet (for use with the measuring bar) lating the average of Columns C and D, or
-15
M.I. 100
5. Column F is the STEP between two adjacent 12. Column M is the same corrected slope change
main bearing bores’ averages per run. Step is data taken from Column K on the front side
calculated algebraically to determine sign of the computation worksheet.
convention using the following equation:
Y,-Y, =Step 1,2 Y,-Y, =Step 2,3 etc. 13. Columns N and 0 are intermediate steps
Example: (4.0)--(S.l)=-1.1, required to obtain the main bearing line bore
(4.3) - (4.0) = 0.3 etc. graph. The values are obtained by calculating
the cumulative sum of the slope change
6, Column G is a constant factor used to adjust figures in Column L, starting at the center of
step when the span between main bearing the engine and working towards the top and
bores is not 16.625” for the purpose of bottom of each Column. As shown on the
calculating EFFECTIVE STEP. This is only example worksheet provided, the corrected
necessary on 16 and 20 cylinder engines slope change value for the No. 6 main bearing
because the span distance between the two (-2.2) is algebraically added to the corrected
center main frames is one half the distance slope change value for the No. 5 main bearing
between any two intermediate main frames; (0.9). The total (-1.3) is then algebraically
therefore, the factor of 2 is used. added to the No. 4 main bearing corrected
slope change value (-0.6) ; equals (-1.9) etc.
7. Column H is effective step which is the
product (x’s) of Column F and its cone- The exact same procedure is followed for the
sponding factor in Column G. readings obtained in Column 0. As shown on
the sample worksheet, the corrected slope
8:Column I is the uncorrected cap line slope change value of the No. 6 main bearing (-2.2)
change value which is defined as the algebraic is again algebraically added to the cumulative
difference between two adjacent effective value for the No. 5 main bearing in Column
steps (Column H). N (-1.3). The total (-3.5) is then added alge-
Example: (0.3) - (-1 .l> = 1.4 mils. braically to the cumulative value of the No. 4
main bearing (-1.9) etc.
9. Column J is a slope change correction used to
adjust for sag or crown present within the 14, The figures obtained in Column 0 are used to
measuring bar. This correction value equals plot data points on the main bearing fine bore
twice the amount of sag (neg. -) or crown graph, Fig. A-5, as shown in the example
(pos. +) found in the bar. provided.
NOTE: The bar correction factor is provided with A scale must be assigned to the horizontal
each measuring bar assembly and should lines so that they include the range of values
be checked annually at Electra-Motive. from Column 0. Plot the data points on the
Contact your service representative to graph under the appropriate main bearing
make necessary arrangements to have this position number. The center mains on 16 and
function performed. 20 cyl. crankcases will always be zero data
points. A straight line is then drawn through
10. Column K is the corrected SLOPE CHANGE the two end points and from this line of
value obtained by determining the algebraic reference the vertical bow or crown is
sum of Column 1 and the bar correction value determined.
in Column J.
Example: (I .4) f (-0.6) = 0.8 mils. The sample computation shows the maximum
vertical height of the case occurs at the No. 6
11. The back side of the computation worksheet, main bearing (7.7 mils) and the crankcase is
Fig. A-4 Part 2 of 2, begins with Column L crowned.
-16-
M.I. 100
APPENDIX
NOTE: The following limits apply only when the main bearing stud stretch is .025” + .006”.
TABLE 1
STEEL BORE DIAMETER LIMITS
(DIMENSIONS IN INCHES)
*Reference only. Dimensions obtained after cap reapplication are to be used for qualification.
TABLE 2
LINE BORE ALIGNMENT LIMITS
(DIMENSIONS IN INCHES)
-17-
ML 100
DATE -
I
2 I -2.5 -1.2 -1.8 1.3 1.1
____ .3 I .3 ’
3 2 -1.7 -1.3 -1.5 - .9 .4 -.6 -1.2 A
4 3 -.h -. I -3 I 0.0 .3
A I I / .h!.z$L_51.3-
5 4 0.0 .5 .3 __ I.1 .5 -I ,I -I .2 .I
~ 1.7 I 1.7
6 5 2.0 2.0 2.0 -.5 0.0 .9 .3 1.1 1.4
.6 2 1.2 - .-
7 6 2.8 2.4 2.6 .9 -.4 .5 -.4 2.3 1.5
___ 2.1 1 2.1 -
8 7 5.4 4.1 4.7 ~ -3.8 -1.3 -.5 -_3 5.9 4.3
-1.7 I -1.7 ____~-__
3 9 8 2.8 3.3 3.0 -.6 1 I / -.6 , I.1 , .5 I -.: -. 7 3.0 2.8
B C D E I; G H I J
(COLUMNS)
22263
-2o-
M.I. 100
A B C D E F G H I J T K
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1 2 3.7 4.4 4.0 1.4: :.: -T!-----. 6 .8
.3 - 1 .3 ‘,. ..’ -Ty---- .::. ..;
3 3.6 5.0 4.3 ..’ : .. ::.,.: ....:.
:.;..;..
A --i;r;- ‘Y... ., ::.....
2 1 4.3 5.0 4.6 '.':).: - d .
-. 4 1 -. 4
2 1 3 2 3.7 4.8 4.2 z-+7-- 4 -z.L.- 6 ..-.:..2
- 0.0 1 0.0 .:.y.;.
.‘. ....:- :.
4 3 4.1 4.3 4.2 : :: -.,; .:. ..:.:.. - ;.::::. \
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.,.:.: ?. . :.. .::
3 2 3.9 5.0 4.4 - A --LA--- ..“. ...,.:.: j...: .‘.... .:: ..
-. 3 1 -. 3
3 2 4 3 4.1 4.1 4.1 - 010 -. 6 -.6
3 1 i: ;:i.: :. ‘:.::.; -.: /: ‘...:.:
5 4 3.8 3.9 3.8 -- -. - -. 3 . 1. .::. . :.‘.
. . ..
-L.-e-e - : . ..: .‘.‘.
4 3 4.5 4.7 4.6 -
-.6 1 -. 6
4 3 5 4 4.3 3.8 4.0
9 1 1.5 -..-l.- 6 --G--9
6 5 4.7 5.2 4.9 & - .9 : :
.:
Fig. A-4 - 16 & 20 Cylinder Line Bore Computation Worksheet For Use With
Granite Measuring Bar 8467738 (Sheet 1 of 2)
M.I. 100
.8 I
c I \
3 2 -. 2 -5.4 3.0
8 7 .8 -. 9 6.5
1
1 9 8 1 -1.3 -1.0 6.1
-2.4 4.4
( 11 10 I 1.2 -5 .o 1.7
-6.4 0.0
222658
Fig. A-4 - 16 & 20 Cylinder Line Bore Computation Worksheet For Use With
Granite Measuring Bar 8467738 (Sheet 2 of 2)
-22-
M.I. 100
I
i
M.I. 100
Equipment:
Part No.
Did Bore Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8275258
Mgster (8.25OO”‘Nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9321276
Serration Gauge - Includes Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9081052
Precrush Plates . . . . . . . . . 8488128
Texaco Threadtex’Lubrfcant #i3& (7b lb’. pail) ’ 1: : : 11: 1: 1: : : 1. . . . . . . . . 8307731
Granite Inspection Table . . . . . . . . . . . . . . . . . . . . . . Contact EMD Service Department
For Supplier Information
Support Blocks . . . . File Drawing #778
Dial Indicator Gauge i Case Line’Readings’-‘ThdIe’ Method . : : 1 1 : 1 : : : . . . . File Drawing #891
Measuring Bar . . . . . . _ . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . 8467738
Dial Indicator Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . 8467737