Examining

Specifications
Permissible Out-Of-Roundness: 0.002 mm
Permissible Difference In Cylinder Shape (Over 54 mm Length):
Conrod Bearing Journals: 0.010 mm
Crankshaft Bearing Journals: 0.010 mm
Permissible Axial Runout: 0.02 mm
Filet Radii At The:
Crankshaft Bearing Journals: 1.9 - 2.1 mm
Conrod Bearing Journals: 1.9 - 2.1 mm
Bearing Journals Ground And Presision Lapped (refer to footnote [1]): 0.15 mm
Crankshaft Journal Diameter At Front: 31.98 - 32.00 mm
Permissible Difference In Concentricity Of Front Crankshaft Journal (refer to footnotes [2] and [3]): 0.05 mm
Contact Surface Diameter For Radial Seal At Rear: 92.874 - 92.928 mm
Permissible Difference Of Rear Crankshaft Flange:
Axial (refer to footnote [2]): 0.04 mm
Radial (refer to footnote [2]): 0.015 mm
Premissible Difference In Concentricity Of Crankshaft Bearing Journals (refer to footnotes [2] and [4]):
Journal 2 and 6: 0.07 mm
Journals 3, 4 and 5: 0.014 mm
Scleroscopic Hardness Of Crankshaft And Conrod Bearing Journals:
When New: 74 - 84 mm
Limit Value (refer to footnote [5]): 60 mm
Permissible Imbalance Of Crankshaft When Mounted In Journals 2 and 6 (refer to footnote [6]): 100 gram

[1]: Maximum peak-to-valley height (Hz).
[2]: With crankshaft mounted on crankshaft bearing journals 1 and 7 and one full revolution.
[3]: If measurement made with crankshaft installed, eliminate radial bearing play by applying pressure to crank journal.
[4]: When the crankshaft is mounted on the crankshaft bearing journals in front of and behind the crankshaft crankshaft bearing journal to be measured and one full revolution, permissible difference 0.04 mm.
[5]: The limit value must exist at, at least 66% of the circumference of the journal.
[6]: Related to the 1st and 12th balancing weight at 550 RPM when mounted on the 2nd and 6th crankshaft bearing journal.

NOTE:
^ Maximum wear limit of crankshaft and conrod bearing journals is 0.02 mm.
^ The repair sizes listed in the table should be adhered to exactly.
^ When re-grinding, it is essential to maintain the fillet radii at the crankshaft and conrod bearing journals.
^ All the radii of the conrod and crankshaft bearings are inductively surface hardened, at the 2nd, 3rd, 4th, 5th and 6th crankshaft bearings.
^ The running surface for the rear radial seal is inductively hardened to a depth of about 1 - 2 mm.

Crack Testing
Clean crankshaft. The bearing journals must be free of oil and grease.
Magnetize crankshaft and apply fluorescent powder (flux).
It is also possible to use a dye penetration method (immersing in bath or using a spray can).
Aid:
dye, UV oil or fluorescent powder
cleaning product
developer

Hardness Testing





Test hardness with the drop handness tester (sclemscopic hardness). The minimum hardness of 60 scale values must exist at 2/3 of the circumference of the journal.

Hardening





Always harden journals with hardened radii (arrows) inductively.
If this is not possible, scrap crankshaft.

Inspecting Hardening
The setting of the hardening system should be checked by taking metallographic sections in order to achieve proper hardening.

These sections can be taken from test hardenings on scrapped crankshafts.

Check hardening by etching the surface of the journal with a 2% alcoholic nitric acid (HNO3).

No dark patches should appear on the surface of the journal.

The hardened radii must be just as bright as the surface of the journal.

The non-hardened radii darken in color.

As a comparison, it is recommended to perform etching on a journal which has been metallographically checked.

Following this, carefully wash off the nitric acid with alcohol.

Corrosion Protection
Crankshafts which are not re-installed immediately, must be oiled with a corrosion protraction oil.

Examining, Grinding And Hardening Flow Charts
Proceed in the order stated in the diagram when examining and servicing crankshafts.

Section A

Section A: Examining, Grinding (Part 1 of 2):

Section A: Examining, Grinding (Part 2 of 2):

Section B

Section B: Hardening: