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Home , Connecting rod, Crankshaft, Cylinder head, V engine

BF Products in Focus 2nd edition 09/2014 (082016) Item number 50 020 042-02

Edited by: Motorservice, Technical Market Support

Layout and production: Motorservice, Marketing DIE NECKARPRINZEN GmbH, Heilbronn

This document must not be reprinted, duplicated or translated in full or in part without our prior written consent or without reference to the source of the material.

All content including pictures and diagrams is subject to alteration. No liability accepted.

Published by: © MS Motorservice International GmbH

2 | Products in Focus Technology and service with tradition

Contents Page

Crankshafts 4

Camshafts 6

Connecting rods 8

Cylinder heads 10

Water 12

Oil pumps 14

Flywheels 16

Crankcases 18

Products in Focus | 3

Product range • Forged crankshafts for: - - industrial engines - gas engines - engines for agricultural and forestry • accessories: - toothed wheels - rings - counterweight bolts

Crankshafts in Focus

• The crankshaft in the has the • To ensure high quality standards, most the crankshaft accessories are also task of converting the up and down BF crankshafts are produced on own replaced. movement of the into a rotary tools and are subject to stringent motion with the aid of the connecting checks. rods. This is transmitted to the • Due to the high levels of stress . encountered in the utility vehicle sector, • Two types of crankshaft are produced, BF follows the OE specifications and cast and forged, with integrated or offers predominantly forged bolted-on counterweights. The pistons, crankshafts. connecting rods and crankshaft together • To ensure the durability of the newly form the . installed crankshaft, we recommend that

4 | Products in Focus Forged counterweights Bolted-on counterweights Twisted journals e. g. OM 611 4- in-line engine e. g. OM 335 6-cylinder in-line engine To allow for other crankshaft angles at the connecting rod journals, the crankshaft is heated again after and twisted at the points. e. g. OM 906 6-cylinder in-line engine

Offset connecting rod journals Two connecting rods per connecting rod e.g. OM 501 6-cylinder journal e.g. OM 422 8-cylinder V engine

Products in Focus | 5

Product range • Camshafts for truck, industrial and gas engines • Engines for agricultural and forestry machines • accessories, such as - - push rods - rocker arms - brackets

Camshafts in Focus

• The camshaft is driven by the crankshaft the push rods and rocker arms, in turn • To preserve the durability of newly via the drive gear, and in turn controls governing the exchange of gas in the installed camshafts, we recommended the valve train of the engine. The engine. replacing the following parts at the same camshaft helps to ensure that the • New generation truck engines have time: and exhaust open and close at overhead camshafts. In-line engines - pre-determined times. have a maximum of two camshafts, - push rods • The duration of opening, valve V engines may be fitted with as many as - set and movement of the valve on opening four camshafts. - camshaft bearings and closing are determined by the shape • The camshafts are subject to bending - rocker arm of the . and torsion forces. To withstand these • Camshafts are fitted below the high levels of strain over the long term, in approximately 60% of all the camshafts in the BF product range truck and industrial engines. The intake have been designed with high strength and outlet control the intake and properties. Camshafts may be cast or exhaust valves of the via forged, depending on their intended purpose.

6 | Products in Focus Standard camshaft Intake camshaft Outlet camshaft The camshaft actuates both the intake and If two camshafts are used, the intake The exhaust valves are actuated by the exhaust valves. camshafts actuate the intake valves only. outlet camshaft as well as the intake To ensure maximum cylinder fill, the cam camshaft. Exhaust valves often have stroke of the intake camshafts is typically a shorter cam stroke than intake greater than that of the exhaust camshafts, which can be attributed to the camshafts. higher pressure difference at the exhaust for discharging combusted gases.

2 3 1

4

5 1 Valve 2 Valve-spring 3 Rocker arm 4 Push rod 6 5 Tappet 6 Camshaft

Combined camshaft Overhead camshafts Bottom-mounted camshafts 3 cams for PLD injection systems: Where camshafts are overhead, the Where camshafts are bottom-mounted, • intake cams valves are opened directly by the cams the tappets and push rods transfer the • outlet cams via the tappets, rocker arms or finger stroke of the camshaft to the rocker arms. • cams as and nozzle unit drive type rockers. Overhead camshafts are The rocker arms push open the valves used only with multiple cylinder against the force of the valve springs. heads.

Products in Focus | 7 Connecting rods

Product range • Parallel and trapezoidal connecting rods - Cracked - Toothed - Sawed • Accessories: - connecting rod bolts - conrad bush

Connecting rods in Focus

• Connecting rods form the link between • The connecting rod is mounted on the • Connecting rods must be replaced if they the crankshaft and the pistons and crankshaft via conrod bearing are broken or bent, or if the mountings of transfer the gas and inertial forces to the shells. The large connecting rod eye is the connecting rod are deformed. on the crankshaft. The divided for mounting on the crankshaft. If the other connecting rods are free from connecting rod pushes and pulls the The connecting rod often has a damage, the connecting rods in utility into and out of the cylinder. between the small and the large vehicles can also be replaced • The small, undivided connecting rod eye connecting rod eye for supplying the individually, providing the same type is on the piston side for mounting the piston pin with lubricating oil. used. piston bolt has a connecting rod bearing • The connecting rod is forged from , bush. with either alloyed steel or annealed steel used depending on the strain.

8 | Products in Focus Straight separation Angled separation

Straight and angled separation Cracked joint faces Milled or polished joint faces For very large crankpins, connecting rods Cracked connecting rods are initially Another procedure for producing the may be separated at an angle. This is produced as a single unit, then given break connecting rod bearing cap is separation necessary to allow the connecting rod to lines (sinter rods) or laser notches (steel or cutting. The large connecting rod eye is slide into the cylinder, in spite of the large connecting rods) and split (cracking) into cut apart, the joint faces are then milled or connecting rod eye. When using two parts. Both parts are screwed together polished. The connecting rod bearing cap connecting rods with angled separation, when the connecting rods are assembled, is then fixed with locating bolts or pins. the installation position must be observed, with the point of fracture ensuring that the especially in in-line engines. rods fit together precisely. Connecting rods and connecting rod caps must always be used together on account of their breakage geometry, they cannot be interchanged. Cracked connecting rods offer more advantages in terms of strength, cost and production accuracy. Once assembled, the joint faces are barely visible. Connecting rods and connecting rod caps fit together very precisely, thus allowing maximum force .

Parallel and tapered connecting rods Ever-increasing combustion pressures are Parallel Usable area increasing the stresses on piston pin connecting rod mountings on connecting rods. To better absorb higher forces, the usable area of the connecting rod bearings has been increased by using tapered connecting rods.

Tapered connecting rod

Products in Focus | 9 Cylinder heads

Product range • Comprehensive range of cylinder heads for all conventional truck engines and to suit various Euro standards. • Accessories: - cylinder head bolts - valve springs - valve spring retainers - valves - inserts

Cylinder heads in Focus

• In combustion engines, the cylinder • The cylinder head is one of the more • The combustion process that takes place head sits above the pistons in the complex components of a motor, in the cylinder exerts a high amount of . requiring complex manufacturing force on the cylinder head, so it is vital • The cylinder head is positioned above processes. In addition to holding the that the tightening of cylinder the cylinder block and the . described components, the cylinder head bolts always match those specified • The cylinder head accommodates the head also has to fulfil the following by the manufacturer. key components for mechanical control tasks: • The tightening sequence of the cylinder of the gas exchange, including: - sealing the combustion chamber head bolts is important for preventing - intake and exhaust ducts for charge - absorbing the combustion power deformations. If the manufacturer’s exchange process - supplying the moving components of instructions are not observed, harmful - valves and accessories the valve train deformations may occur on the cylinder - rocker arms or finger type rockers - heat dissipation through coolant head, on the cylinder of the cylinder - tappets channels and cooling liquid with water- head gasket or on the valve seat inserts. cooled motors, or via large-scale cooling fins (blower) with air-cooled motors.

10 | Products in Focus Single cylinder heads Multiple cylinder heads • The majority of truck engines feature Multiple cylinder heads are typically used single cylinder heads. in passenger vehicles and in new • There are various types, e.g. water- generation truck engines. V engines with cooled cylinder heads from grey cast multiple cylinder heads have one cylinder iron (see picture left) and air-cooled head for each cylinder line. In engines with cylinder heads from aluminium multiple cylinder heads, camshafts are (see picture right). often accommodated in the cylinder head. • In the event of damage, they can be Engines with multiple cylinder heads are replaced individually. always water-cooled by design.

Water-cooled cylinder heads Air-cooled cylinder heads Constant Modern engines are almost exclusively The air is blown directly onto the engine. All buses over 5.5 tonnes and over water-cooled with a coolant mixture of To increase the size of heat-dissipating 9 tonnes must be fitted with a continuous water and anti-freeze/anti-corrosion surfaces, cylinders and cylinder heads in braking mechanism. With constant agent. air-cooled engines have large cooling ribs. or decompression brake, an additional Advantages: Advantages: valve is opened at the end of the • Water can absorb and dissipate larger • more straightforward, cost-effective compression cycle. The gases for quantities of heat. construction method compression are drawn into a separate • Cooling ducts between the cylinders and • more reliable operation chamber and then fed back into the cylinder head can achieve more effective • reduced weight combustion chamber or directly into the cooling within the engine. • coolant does not freeze in low ambient exhaust pipe. This ensures that no new • Cooling requires less power than cooling temperatures pressure is exerted on the crankshaft fans used in . during the combustion cycle, preventing new drive force from being generated. The valve is controlled pneumatically or hydraulically. The constant throttle helps to achieve a braking power of 14–20 W per litre displacement.

Products in Focus | 11 Water pumps

Product range • Water pumps with and without pulley • Poly-rib , V-belt or gear driven water pumps • Repair kits for BF water pumps

Water pumps in Focus

• Water pumps are responsible for • Water pumps are attached to the outside circulating coolant in the engine cooling of the and can be replaced system. without having to open the engine. • Water pumps are typical wear parts, • Depending on their installation location which must sometimes be replaced on the engine, water pumps are driven several times during the service life of by V-belts, poly-rib belts or gears. an engine. In the event of engine • With water pump malfunction the engine reconditioning, the water pump should overheats, which can result in serious always be replaced to safeguard engine damage. operational safety.

12 | Products in Focus Mechanical water pumps Mechanical water pumps for trucks are The housing consists of aluminium or grey driven by V-belts, poly-rib belt or directly . Various attachments are fitted to by the crankshaft using gear wheels. the pump housing, depending on the type of pump, and may include brackets for Various types of closed and open pump hoses, , plugs, etc. impellers are used in the mechanical water pumps. The latest calculation methods and Motorservice offers a wide range of repair flow simulation tools are used to optimise kits for BF water pumps. the pump impellers in terms of the hydrau- lic requirements, the pump efficiency and All BF water pumps are supplied with the the geometry, taking into account the necessary sealing set for replacement. ­manufacturing process. The and mounting of the water pumps always form a complete unit. This includes special BF repair kits.

The drive shaft and the bearings of the water pump always form a complete unit. This applies also for the BF water pump reapair kits.

Products in Focus | 13 Oil pumps

Product range • Oil pumps with plug-in drive • Oil pumps with chain drive • Oil pumps with gear drive

Oil pumps in Focus

• The oil pump sucks oil from the oil pan • Oil pumps are generally replaced as and supplies it to the and oil complete unit. They are not intended to cooler, from where it passes along oil be reconditioned. ducts to the engine's lubricating points. • Oil pumps have high durability. Factors • Due to their purpose and the way they such as: function, oil pumps are installed inside - poor oil quality the engine. - oil dilution • When the oil pump is replaced, the - dirt engine must either be opened or - engine damage dismantled, depending on the pump can significantly decrease their design. durability. It is therefore necessary to change the oil pump prematurely.

14 | Products in Focus Gear type pumps Rotor type pumps

Gear pumps Rotor pumps • Gear type pumps are mostly in the form • Rotor pumps are able to generate high of plug-in pumps or pumps with gear or delivery rates and high pressures. chain drive. These oil pumps are driven indirectly by the crankshaft. • Compared to chain driven oil pumps the design of gear driven or plug-in oil pumps allow a more easy replacement.

Products in Focus | 15

Product range • Single and dual mass flywheels • rings

Flywheels in Focus

• Flywheels are produced from grey cast torsional vibration damper. The vibration • Some flywheels are notched as this iron or steel and form a friction lock damper absorbs and dampens torsional helps with the adjustment of the between the crankshaft and the drive vibration, thus reducing the resonance injection system. train via the . in the gearbox and drive train. • The main function of the flywheel • Other tasks of the flywheel include is to compensate for rotational accommodating the clutch with drive irregularities of the crankshaft. This plate and pressure plate. helps to drastically reduce the transfer • The starter motor for starting the engine of engine vibrations to the drive train. is connected via the external shrunk-on • Dual mass flywheels feature two ring gear. components – the flywheel itself and a

16 | Products in Focus Single mass flywheels Dual mass flywheels Starter ring gears By storing kinetic energy, flywheels help The flywheel mass is divided into primary The ring gear transfers the force of the to compensate for uneven running and and secondary mass. The two masses are starter to the crankshaft via the flywheel. vibrations in engine operation. linked by torsion damping springs. The This initiates the start procedure of the dual mass flywheel demonstrates engine. On older engine types, the ring excellent vibration damping capabilities gear also has the task of communicating and impresses in every aspect. the TDC position to the engine control via the TDC sender. It is also used for setting the control times

Engine side Ring gear Clutch side

Products in Focus | 17

Product range • Crankcases for in-line engines • Crankcases for V engines

Crankcases in Focus

• As the housing for the drive mechanism - integrating a crankcase ventilation and cooling jacket, the crankcase forms system the central component of the engine. - connecting to the gearbox and valve • The crankcase has a number of functions control drive and tasks, including : - accommodating various auxiliary - accommodating the crank drive components mechanism - closing the crankcase to the outside - accommodating and connecting the by means of the oil pan. cylinder head(s) • BF crankcases are produced primarily - as a mounting for the crankshaft and, from grey cast iron by sandcasting. if applicable, the camshaft - accommodating lubricant and coolant ducts

18 | Products in Focus Crankcases for in-line engines Advantages: • Balanced engine running, even without mass balancing. • Straightforward, cost-effective construction method.

Disadvantages: • Longer construction method when compared to comparable V engines.

Crankcases for V engines Advantages: • Shorter and more compact model when compared to comparable in-line engines. • Shorter model for crankshafts and camshafts.

Disadvantages: • More cost-intensive construction method. • Takes up more space (width).

Products in Focus | 19 Know-how transfer

Professional knowledge from the experts

Worldwide training Technical information Technical videos Direct from the manufacturer From practical experience for Professional installation clearly Each year, around 4,500 mechanics and practical use illustrated engineers benefi t from our training courses Our Product Information and Service Knowledge transfer via video: In our videos, and seminars, which we hold on-site in Information publications, technical you will fi nd practice-orientated fi tting locations across the world or in our training brochures and posters keep you at the instructions and system explanations centres in Neuenstadt, Dormagen and forefront of the latest technological relating to our products. Asperg (Germany). developments.

News Social media Individual information Regular information via e-mail Always up to date Especially for our customers Subscribe online to our free newsletter now We provide extensive information and and receive regular information about services relating to our wide range of additions to the product range, technical services: e.g. personalised sales-promoting publications and much more. materials, sales support, technical support and much more.

20 | Products in Focus PI SI For technical personnel only Page 1/2

ngine bearings with polymer coating Tips and tricks ... for correct installation and long service life of the new short block Systemkomponenten und Service für eine fachgerechte Reparatur

• Please note that cylinder heads which • Check the correct operation of the vis- until oil pressure has built up, so that all may be included in the delivery are not cous . bearing points have been supplied with fully assembled. These must be aligned • Clean water cooler and check for blocka- oil before initial start-up. with the or intake • Check for correct function in the oil manifold and the cylinder head bolts pump, oil pressure control valve, water must be tightened according to the charge air cooler thoroughly and check pump and vibration damper. for blockages, it is imperative to replace • • Clean all attachments thoroughly before this in the case of previous - installation and check for damage. damage. cle manufacturer. • Clean oil cooler thoroughly and check for • Check engine monitoring instruments for blockages, it is imperative to replace this correct operation and replace in case of in the case of previous engine damage. defects. – 04/15 EN

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Products in Focus online OnlineShop Get information on the products Your direct access to our products online Order at any time. Quick availability check. Interactive elements, animations and Extensive product search by engine, video clips provide interesting information vehicle, dimensions etc. about our products in and around the engine.

Technipedia Motorservice app Are you looking for technical Access technical know-how on the information relating to engines? move We share our know-how with you in our Here, you will fi nd the latest information Technipedia. You can get professional and services relating to our products knowledge direct from experts here. quickly and easily.

Products in Focus | 21 22 | Products in Focus High performance for high loads.

Service life of three million kilometres, daily load of 30 tonnes.

The drives of utility vehicles have to withstand particularly high stresses. The reliability of drive components is an ab- solute necessity to keep the total costs of ownership low.

Under the brands KOLBENSCHMIDT and BF, Motorservice sells system components of the highest quality which are designed for a long service life and efficient repairs. www.ms-motorservice.com

Products in Focus | 23 Motorservice app Mobile access to technical know-how

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50 020 042-02 – EN – 08/14 (082016) © MS Motorservice International GmbH