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EMD M.I. 100 Bore Alignment Qualification
EMD M.I. 100 Bore Alignment Qualification
EMD M.I. 100 Bore Alignment Qualification
M.I.100"
MAINTENANCE INSTRUCTION
*Rev. C
SECTION I I
[
I
DETERMINING IF LINE BORE IS J
REQUIRED
Obvious failures involving the main bearing/crank-
shaft system will requirecomplete disassembly of the
18302
engine and in almost all cases will also require line
bore. However, those engines which have been taken Fig. 1 - Main Bearing Bore Measurement
ENGINE DISASSEMBLY
1
REQUALIFY MAJOR
COMPONENTS
I
INSTALL CRANKCASE
IN A SUITABLE
TRUNNION FIXTURE
I
REMOVE MAINBRG. CAPS,
BEARINGS & SHAFT
I-
NOTE MAIN BRG. CONDITION
- REF. INSP. BOOK
I I
APPLY MAIN BRG. CAPS
1- Al1± '5
567 & 645
MILS STUD STRETCH I
w/PRECRUSH PLATES - 1-1 B. 35 ± 6 MILS STUD STRETCH 1 710
.SEAT SERRATIONS -----------
I I
LINE BORE - CAPS
1
------1
1- A."12± S MILS
B. 39± 6 MILS
------
STUD STRETCH
STUD STRETCH
I
1
TORQUED TO 25 ± 5 MILS
(567 & 645) OR 28 ± 5 MILS
(710) STUD STRETCH
I
MEASURE VERTICAL STEEL
BORE DIAMETERS ~ 1- SEE TABLE1IN APPE
FAIL 1 - -1 __ ~OR SPECIFICATION
Y
REMOVE MAIN BRG.
PASS
1-1
1- Al1±"5
567 & 645
MilS STUD STRETCH
B. 25 ± 5 MILS STUD STRETCH
1
1 710
CAPS & REAPPLY
-----------
I
MEASURE STEEL BORE
DIAMETERS - RECORD DATA
l-J 1
------I_"c28±~MIlS.
1- A."12 ±S MILS STUD STRETCH
STUD STRETCH,
I
1
PASS
---------
REQUALIFY C'CASE BORE
ALIGNMENT/GRANITE
TABLE OR MEASURING
BAR METHOD
I
CALCULATE BORE ~ I FACTORS
CONDEMN'NG"
ALIGNMENT DATA 1 BORE:
- -I A. SLOPE CHANGE
FAIL 1 B. CAP TILT
Y 1 C. VERTICAL BOW
/
PASS
---------
REASSEMBLE ENGINE WITH
QUALIFIED COMPONENTS - LOAD
TEST & BRG. INSP.
-2-
M.I.100
To qualify any main bearing nut torque application Measurement from the centerline of No.2 serration
system, perform the following: on one bank to the centerline of the No.2 serration
on the opposite bank must be 9.500" ± .010"
1. Select twelve studs which have been prepared (241.30 ± 0.25 mm) on 567 and 645 engines, and
normally for main cap application. (See Section IT, 10.500" ± .010" (260.35 ± 0.038 mm) on 710
Item C.) engines.
4. Loosen nuts.
-3-
M.l. 100
3.571 ± 0.127 mm
.1406 ± .0050"
(A)
34820
-4 -
M.I.100
Following line bore, measure the vertical steel bore GRANITE TABLE METHOD
diameters. All bore measurements are to be taken 112"
(12.7 mm) in from the generator side and 112"in from The crankcase should be placed right side up on the
the accessory side of each MFM. Vertical diameters precision granite table as shown in Fig. 4. It must be
should be within the 8.251" to 8.249" (209.58 to supported on its base rails as follows:
209.52 mm) limits for 567 and 645 engines or 9.251"
to 9.249" (234.98 to 234.92 mm) limits for 710 engines 20 cylinder - Supports centered 28"
as shown in Appendix Table I, or reworked and (711 mm) from ends of
requalified. crankcase
Remove pre-crush flat plate 8488.128. Remove all 16, 12, 8 and 6 Supports centered 12"
caps. cylinder - (305 mm) from ends of
crankcase
E. RECAP APPLICATION FOR MEASURE-
MENT OF VERTICAL BORE Preferably, the crankcase should be leveled so that dial
indicator readings at the top of the two end MFMs are
The purpose of this recap operation is to ensure that the same. However, a difference of within .010" (.25
proper seating of the MFM and cap serrations was mm) will not adversely affect results. In either case, set
attained prior to line bore. dial indicator to zero for reading at accessory end of
No.1 main bearing bore."
1. Assemble main bearing caps with standard washers
and nuts. Apply Texaco Threadtex No. 2303 The granite table's sole purpose is to provide the
liberally to both sides of washer, stud threads, and source of reference for determining vertical bore
nut face. alignment (case line data). This data, along with the
recap steel bore diameter readings (Section II, E 5) is
2. Record free length on the four studs selected in used to mathematically compute several alignment
crankcase machining. functions.
)
./
3. Tighten all nuts in two steps as follows: The case line readings, Fig. 5, are obtained using a dial
indicator mounted on a surface gauge, 112" (12.7 mm)
a. Apply torque to produce 11 ± 5 mils stud in from each main frame accessory and generator end
stretch on 567 and 645 engines (12 ± 5 mils face and must be made with all caps applied and
on 710 engines) or 475 Nrn (350 ft-lbs.) Ref. torqued per Section II, E above. Take two independent
torque. sets of dial indicator readings. Any discrepancies
b. Apply torque to produce 25 ± 5 mils stud between individual readings which are in excess of
stretch on 567 and 645 engines (28 ± 5 mils .0005" (0.013 mm) must be resolved. Record the fmal
on 710 engines) or 1017 N·m (750 ft-lbs.) corrected readings on the computation worksheet for
Ref. torque. Granite Table Inspection (sample provided in the
Appendix Section).
4. Measure and record length of the four selected
studs.
Before mathematically computing the alignment func-
tions on the worksheet it is very important to
5. Remeasure steel bore diameters. The readings understand each of the functions from a physical
obtained must fall within the cap reapplication standpoint. The following definitions are provided
limits shown in Appendix Table 1. Record the
along with an appropriate figure to explain each
vertical diameters in the appropriate columns on alignment concept.
the Computation Worksheet. '
1. Case Line -
SECTION III
-5-
M.l. 100
"
22254
20
CYL.
ENJ48 115
)'
- 6-
M.L 100
NOTE
For ease in calculating data, record as mils;
where .001" (0.03 mm) equals 1.0 mil.
NOTE
Dial indicator readings are recorded as positive
(+) when gauge travel is towards the topdeck and
. negative (-) when gauge travel is away from the
topdeck. Because of the inverted position of the
gauge dial indicator, plus (+) gauge readings are
recorded as minus values.
The maximum deviation of the center of anyone 4. Column E is the STEP between two adjacent main
main bearing bore from a line drawn through the bearing bore averages. Step is calculated algebrai-
centers of the generator and accessory end main cally to determine.' sign convention using the
bearing bores is the crankcase vertical bow. The following equation:
16 cylinder crankcase shown in Fig. 8 has a
maximum bow of -.003" (-0.08 rum) or -3 mils Y2 - Y1 = Step 1,2 Y3 - Y2 = Step 2,3 etc.
sag. Positive bow is referred to as crown.
Example: (-1.5) - (-1.8) = +0.3,
4. SteplEffective Step - (-0.3) - (-1.5) = +1.2 etc.
-7 -
.--r---------r-------r---j-·-----l---T------·--· ....
s;::
1-<
....
o
o
GENERATOR
END
Gen.
End
Case Line
Steel Bore
Diameter
00
Measurements
Cap Line
Case
MFM's Line
("A" Frames) Readings --
Not To Scale. Line Bore Taken At
Conditions Shown Are Each Bore
For Illustrative Purposes
Only.
GRANITE TABLE
22255
.:»
'·""M,.. .•••·
-.
-3.0
';'~f-#"-#t-l-- - - --
\0
GRANITE TABLE
22256
(
a::
!--<
.....
8
I
Sign Convention
Case Line Data 5 = + Towards Top
Case"Une Step" +0.002" (0.05 mm) Deck (See Pg. 7)
or +2.0 Mils
Cap Line Step Case Line Data 4 =
+0.0003" (0.008 mm)
, -----r
EXAMPLE: ~ Case Line Data 6 = Case Line Step" or +0.3 Mils
+0.3 Mils
"Case Line Step = Cap Line Step
EXAMPLE:
l~
Step 5
Case Line Data 6- I I
I I Step ~
Case Line Data 5 "Case Line Step =
or
Step~=-1.7
+2.0 - (+0.3) = +1.7
EffStep~=-1.7(2) 4
= -3.4 Step 5 = +1.7
EffStep~=+1.7 (1)
Not To Scale, Line Bore = +1.7
Conditions Shown Are 8-5/16"(211.14mm) , 1-16-5/8" (422.28mm)-----!
For Illustrative Purposes
Only.
SLOPE CHANGE @ #4
'Case Line
<, Cap Line
1_ J _
___r ----- - -- -- - -1- . Sign Convention
+ Towards Top
Deck (See Pg. 7)
•...•
•...•
34817
Fig. 10 - Slope Change Vs. Step (Zero Slope Change Illustrated) NOTE
Single Dot • represents average s=
~
of measurements 112 from out- •....
side end faces. 8
f
r ---, r------r- 'I '1 J -_. W I I -r---Y- r··'·--r-·----·-r 'T
·Case line
Cap Line
-,
- - - -
j
- - -
J _ Sign Convention
_J--.,---+------
-r-- - - --------
Step;
t
-0.004"
+ Towards Top
Deck (See Pg. 7)
Step 34 +0.004"
(-0.10 mm)
,0.008" (+0.10 mm)
"Case Line
Slope Change
•....
N $C4 =
S 3_ S 2 =
4 3
+4.0-1-4.0) =
34818
8. Column I is the algebraic difference between the 12. Columns Nand 0 are the cap line calculations for
case line readings at the generator end (Column C) the accessory end and generator end respectively.
and the case line readings at the accessory end It is the algebraic difference between the case line
(Column B) which equals case line tilt (per gauge dial indicator readings and the steel bore variation
length), or ZG - ZA or (-1.2) - (-2.5) = +1.3. =
from nominal; or Column B - Column J Column
=
N etc. and Column C - Column K Column 0 etc.
9. Columns J and K are vertical recap steel bore Example: (-2.5) - (+1.1) = -3.6 and
variations from the nominal bore diameter of (-1.2) - (+1.3) = -2.5 etc.
8.2500" (209.550mm) on 567 and 645 engines or
9.2500" (234.950mm) on 710 engines, taken at the 13. Column P is the average ordinate for cap line at
accessory end and generator end respectively; The each main bearing bore and is calculated the same
following sign convention is used: pos. (+) = as the average ordinate for case line (Column D).
=
Larger than nominal and neg. (-) Smaller than
nominal. Example: A typical vertical steel bore 14. Columns Q through T are used to calculate CAP
dia. of 8.2511" (209.578mm) is expressed +1.1 LINE step, effective step and slope change. The
mils; 8.2488" (209.52Omm) is -1.2 mils. calculations are identical to those used to find case
line, step, effective step and slope change
10. Column L is the steel bore difference, which is the respectively in Columns E, F, G, and H.
accessory end steel bore size minus the generator
end steel bore size. The main bearing line bore graph (master and example
Example: (+1.1) - (+ 1.3) = -0.2. sheets provided in Appendix) is used to determine
vertical bow. The numerical values listed in Columns
11. Column M is the CAP TILT per gauge length. D or P on the worksheet are used as the data points on
CAP TILT is also equal to the difference of the graph. A scale must be assigned to the horizontal
column N from column 0 or cap line calculations lines on the graph so that they include the range of
generator end minus cap line calculations acces- values from either Column D or P. Plot the data points
sory end. Example: (-2.5) - (-3.6) = +1.1. It is on the graph under the appropriate main bearing
equal to the algebraic sum of Columns I and L or position number. Draw a straight line to connect the
) case line tilt plus steel bore difference. Example: two end data points and from the line of reference
=
(+1.3) + (-0.2) +1.1. determine the max. vertical sag (-) or crown (+).
~;:.
- 13 -
I ' T
a::
~
•....
8
Case Tilt =
Case Line Data, Gen. -
Case Line Data, Ace.
or
I
Sign Convention
+ Towards Top
Deck (See Pg. 7)
"ZG - ZA or
3.6 -3.4 = +0.2
Cap Tilt =
Case Tilt + *Steel Bore Diff.
or
lI __
+0.2 + (-.6) = -0.4
----
= +.2
1
, < (
Acc. End Steel Bore - Gen. ------------1 £ <
I
End Steel Bore
or
+1.4 - (+2.0) = -0.6
•....
.;,.. Recap Bore
I I ~ Diameters
Gauge Length From Nominal
NOTE
Measurements on top of
Zero Reading At
bore to be taken 112" from
outside of end faces. Dots
__ 1_ Accessory End Of
No.1 Main Bearing
on bottom represent calcu- Bore
lated points.
- - -rC~p Tilt = -0.4
+3.6 +3.4
For Illustrative
Only. *
pu_~rp~o~s_es_....;L
_ =:::::::-::t~;-;~
± tl.-__
..:c:..:ra::n:k:;:ca:s:.:::eS:.:/N.:.:.7.:5:J3:-.:.1:.50~7~
GRANITE TABLE
34819
APPENDIX
TABLE 1
STEEL BORE DIAMETER LIMITS
(DIMENSIONS IN INCHES)
REMACHINED
REUSE WITHOUT
AS LINE AFTER CAP ANY BORE
BORED* RE·APPLICATION REMACHINING**
567/645 710 5671645 710
P?""! r .Pl~
A:nyOi!i'DiaJJleter (Min.) 8.2490 9.2490 8.2485 9.2485 8.24'75 - ~7~
,(Max.) 8.2510 9.2510 8.2515 9.2515 8:25-35 9-:2535 .,
1-
Max. variation between
accessory end diameter and NO REQUIREMENT ±.002 :!:.OO~
gen. end diameter in anyone
steel bore
Cap Tilt
NO REQUIREMENT r
±.002 £.OtB
(8, 12, 16 Cyl).
Cap Tilt caps 1 & 2 .003 to q;'.001
(20 Cyl.) caps 11 & 12 NO REQUIREMENT ±.002 -.001 to +.003
all others -.002 to +.002
*Reference only. Dimensions obtained after cap reapplication are to be used for qualification.
**Exposed bronze on edges of main bearing requires remachining regardless of cap tilt.
NOTE
The data for 20 cylinder engines reuse without remachining is for crankcases with .011 to .020 sag. The tilt
specifications are obtained by measuring from the accessory end to the generator end. Sag of less than .011
allows for a cap tilt of ±.003. -
TABLE 2
VERTICAL LINE BORE ALIGNMENT L1MITS**
(DIMENSIONS IN INCHES)
REMACHINED REUSE W/O REMACHINING
CASE LINE & OR CAP LINE
MAX. BOW (-) OR CROWN (+) MAX. BOW
20 cyl. /
-.011 +.016 .020
16 cyl. -.006 +.010 .012
12 cyl. -.004 +.007 .008
8 cyl. -.004 +.007 .008
6 cyl. -.004 +.007 .008
Max. slope change - Case Line ±.004* ±~OO6*
Thousandths/16.625" Cap Line ±.OO5 ±.OO8
\
- 15 -
**Also applies for honzontal alignment,
- 91 -
T _ _ _ rn
20 Cyl.
I
16Cyl.
I ;>
N _
;;
0
'"
'"
CD
CD
•.••
•.••
0.
0.
•.••
•.••
.••
.".
w
W
'"
. N
-
- Main
Bearing
Number
Z
o
2!
m
III
rn
Case Line ;0
to Indicator
;;
Readings
~
z
Ace. End 9
Case Line
(j Indicator
Readings
Gen. End
Average
" (Ace. & Gen.)
2
m ~
Case Line
.,
cO'
'Tl@ - - - - - N - - - - - Factor
•••••••
;j;~i~;:
::~::::.
» ,
....•. o ••
/.
•••
{ Effective
Step,
Case Line
....•.
0) Slope
S20 ::c Change,
I\) Case Line
o
.,'<o
0-'
•.•:3
- Case Tilt
Cg. Bore
en'"
(1)0 ~ ~ ~~
~iiJ
8 From Normal,
;:::0::3 1---1-_-+-_+--+_4 ~ Ace. End
:J";;r;;
~ ~
-;£
:Ten
~ ~ Variation
(1)(1) From Normal,
Gen. End
{j)C
•.•:3 Steel
~(1)
~ ~
;:::0: OJ Difference,
<DO (Acc. - Gen.)
~(D
crO ~ ~~
-0
(1)3
.-
"0
c
~
O·
Z
Cap Line
Calculations,
Ace. End
:J
Cap Line
~ o Calculations,
Gen. End
~
::J"
.-
<D
<D
...,
Average
(Acc. - Gen.)
2
o···jl! ~~~Line o
;<l
~
~~N~ ~
o
;<l - - - - - '" - - - - - Factor >
'"m
'"m
;<l
••••••.•
Effective
;; t:J
N
N
C/lii Step, ~ >
N
: Cap Line Z ~
'"'" o m
~ I::;!!J ~~:nege,
~i Vi c~~~
001 TW
'""".1'''/
OATE _
ENGINE SERIAL NO. 7603-1505 CRANKCASE SERIAL NO. 76A 13
;;j ;;j ~
E 4),uc '" '"
c
~.z ';. ","0 e c co." c§." •.. " " ~<:~c
.g"C g.g-g
~C;Kb'g
~~jN .;J occ.:> "c.:>,
4,) "'"'
c:o>"'-"
4,)
"iit!!u
" ••..u
tiiCi~ u
c..oo
'" 7il
uu< u
c...!:d c
'" ",,,
uuc.:>
" tl
<$ -g-",
CIlU" "
"'-
~ e~ e30u
t.LlV5u
0.",0.
2 I -2.5 -1.2 -1.8 1.3 1.1 1.3 -.2 1.1 -3.6 -2.5 -3.0
.3 .3 2.4 2.4
3 2 -1.7 -1.3 -1.5 .9 .4 -.6 -1.2 .6 1.0 -1.1 -.1 -.6 -2.3
1.2 1.2 .1 .1
4 3 -.6 -.1 -.3 -.6 .5 .3 0.0 .3 .8 -.9 -.1 -.5 1.8
.6 .6 1.9 1.9
5 4 0.0 .5 .3 1.1 .5 -1.1 -1.2 .1 .6 1.1 1.7 1.4 -2.0
1.7 1.7 -.2 -.2
6 5 2.0 2.0 2.0 -.5 0.0 .9 .6 .3 .3 1.1 1.4 1.2 1.6
.6 2 1.2 .7 2 1.4
7 6 2.8 2.4 2.6 .9 -.4 .5 .9 -.4 -.8 2.3 1.5 1.9 1.8
2.1 2.1 3.2 3.2
8 7 5.4 4.1 4.7 -3.8 -1.3 -.5 -.2 -.3 -1.6 5.9 4.3 5.1 -5.4
-1.7 -1.7 -2.2 -2.2
....
-.l
9 8 2.8 3.3 3.0 1.1 .5 -.2 .5 -.7 -.2 3.0 2.8 2.9 .8
-.6 -.6 -1.4 -1.4
10 9 2.4 2.4 2.4 -1.5 0.0 1.0 .9 .1 .I 1.4 1.5 1.5 -.5
-2.1 -2.1 -1.9 -1.9
II 10 .5 0.0 .3 -.5 .7 .7 0.0 -.5 -.2 -.7 -.4
12
A B C D E F G H K L M N o p Q R S T
~-~ I
o
~
'"
22263
{.;
o 16Cyl. 2 3 4 5 6 7 8 10 16 Cyl.
s::
1 9 ~
o 20Cyl. 1 2 3 4 5 6 7 8 9 10
•....
11 ~ 12
III -- 1111-111 8
III III III [LI- -_111.1 III III III -- III
~
I
(J
w
0
c...
" •....
0
V)
0
ex:
«
3:
0
•....
..
-
00
<t ENG.
ENG. SERIAL NO. _ DATE _
-"~_.~: ··&:~·
•• r-
M.l. 100
A B C D E F G H J K
<Ii en 0..
- .•...
.~ '"0 .~ '"0 Il) -0 eo eo
>-0>- 00::: 00::: N ----
.•... tI) Il) C
.•...
ro C -oro
C
UzU 1l)1-<'"O Il) ____ C Il) U..s:: 0
.•...
.-< Il)..s::
0\0 c 0 c.
;.J~u.J ~O
ro
I-< ••••• .:::
.•... ~U U t)u
o
il
V) I-< Il) Il) Il) Il)
U •
0..'-< C ~+ 0.. .•... C
U 0 ~
U
8 0.. I-<
I-< I-<
I-< 0..
I-< 0
ro -0 Il) ><t: .•...
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roU '- c 0 ro 0 0_
u.5o <t:......, tI) ~......, w ~V5 CQU Uti)
3 2
.. ,
4 3
)
5 4
6 5
7 6
8 7
9 8
10
22265A
Fig. A-4 - 16 & 20 Cylinder Line Bore Computation Worksheet For Use With
/ Granite Measuring Bar 8467738 (Sheet 1 of 2)
- 19 -
M.I.100
M o
~~ ~~
<.,0~o
~
~
sv «.,0
~
Sv~,O~
0'
~o
~f.-$'~
V <;'I
~
'?><:- ~ 0<S' ~
~<S'.~~ ~
~
9O~t;.~v
(;~ ~
'!<..~
(;~«-.
(;V~~<:-~ ~~
<Q~,~~
G(J"'?>»:
<Q~$JQ~
~"v~~ ',,%'
.:::..~' ,?>"0. ~
~ ~'
~••...~ '" V<.rr,;
(;0 C5
-8.8 0.0
2 -7.5 1.1
5 4 .9 -2.2 5.6
8 7 .8 -.9 6.5
11 10 -5.6 1.7
12 -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)
- 20-
\
"'~~t:>:Y'
I (~('
..' .....•' 2 'J !l :) G t 8 9 10
1 ,J
~:::
:/..J
;:1
C \
~;)
~N',:
u:
<c
:~.',~
'" '
':....
0.0
-.002
-.004
-
N
-.006
-.008 Trt:::~:,~~~:·
-
- .01 0 -;"'~-'" .. ... ,.,+
<t.. ENG,
ENC;, SEn fAL .. \10.. __. 76C3-1518
'_M ·........•
·.· ·_~ '" . D/\TE _ .._, ....
22266 2:1-<
Fig. A-5 - Main Bearing Line Bore Graph - 20 Cyl. -
8
SERVICE DATA
EQUIPMENT LIST
Part No.
Dial Indicator Gauge - Case Line Readings - Table Method . . . . . . . .. . . . . . . . . . File Drawing #891
- 22-
M.l. 100
- 23 -
M.I.100
1
.1
1
1
1
1
1
II
,J...
1 Copyright 1992
Electro-Motive Division, General Motors Corporation. All rights re-
served. Neither this document, nor any part thereof, may be reprinted
without the expressed written consent of the General Motors Locomotive
Group. Contact EMD Customer Publications Office.