Procedure To Measure and Straighten Bent Crankshaft PDF

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Producto: ENGINE - MACHINE

Modelo: 3306 ENGINE - MACHINE 64Z
Configuración: 3306 Industrial Engine 64Z05381-UP
Pautas de reutilización y recuperación

Procedure to Measure and Straighten Bent Crankshafts{1202}
Número de medio -SEBF8054-09 Fecha de publicación -12/10/2007 Fecha de actualización -12/10/2007
i02785143
Procedure to Measure and Straighten Bent Crankshafts{1202}

SMCS - 1202
Engine:Commercial All
C-10 (S/N: AKB1-UP; MBJ1-UP; 2PN1-UP; 3CS1-UP; 8YS1-UP; BCX1-UP)
C-12 (S/N: CPD1-UP; TME1-UP; BDL1-UP; MBL1-UP; 9SM1-UP; 1YN1-UP; ALS1-UP; 2KS1-
UP; 9NS1-UP; BCY1-UP)
C-15 (S/N: EGH1-UP; MBN1-UP; 6NZ1-UP; 9NZ1-UP)
C-16 (S/N: W1A1-UP; 7CZ1-UP)
C-18 (S/N: CJP1-UP; MDP1-UP; MEP1-UP)
C-9 (S/N: CLJ1-UP)
C11 (S/N: KCA1-UP)
C13 (S/N: KCB1-UP; LEE1-UP; JAM1-UP)
C15 (S/N: C5E1-UP; C5L1-UP; MHP1-UP; SDP1-UP; B5R1-UP; BXS1-UP; MXS1-UP; NXS1-
UP)
C18 (S/N: DKE1-UP; EJG1-UP; WJH1-UP)
C7 (S/N: JRA1-UP; JTF1-UP; FML1-UP; KAL1-UP; FMM1-UP; SAP1-UP; C7S1-UP; WAX1-
UP)
C9 (S/N: MTB1-UP; SRB1-UP; 9DG1-UP; CKP1-UP; X3R1-UP; C9S1-UP)
Engine:Truck All
Machine Engines: All
Marine Engine:with Turbochargers All
C-12 MARINE (S/N: 9HP1-UP)
C12 MARINE (S/N: C1Z1-UP)
C15 MARINE (S/N: RLA1-UP)
C18 MARINE (S/N: CKH1-UP; C1J1-UP; NAX1-UP; NAY1-UP)
C30 MARINE (S/N: CLX1-UP)
C32 MARINE (S/N: RXB1-UP; RNC1-UP)
C7 MARINE (S/N: C7B1-UP; C7D1-UP; C7X1-UP; C7Z1-UP)
C9 MARINE (S/N: C9B1-UP; CSN1-UP; X9X1-UP; Z9X1-UP)
Agricultural Tractor:
MT855 (S/N: A3A1-UP)
MT865 (S/N: GDA1-UP)
MTC845 (S/N: JAC1-UP)
Articulated Truck:
730 (S/N: 5ED1-UP)
Asphalt Paver:
AP-755 (S/N: C7C1-UP)
Generator Set:
C15 GEN SET (S/N: C5H1-UP; X4R1-UP)
C18 GEN SET (S/N: C6C1-UP; G4C1-UP; STD1-UP; STM1-UP; EKW1-UP; STH1-UP)
C18 MARINE GS (S/N: CYN1-UP; MGS1-UP)
C27 GEN SET (S/N: DWB1-UP; STR1-UP)
C32 GEN SET (S/N: SXC1-UP; WDR1-UP)
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 18/06/2008
C9 GEN SET (S/N: C9E1-UP)

C9 MARINE GS (S/N: C9A1-UP)
C9 MARINE GEN (S/N: SJB1-UP)
Industrial Engine:
C-10 PETROLEUM (S/N: Z2B1-UP)
C-15 IND (S/N: BEM1-UP)
C-16 IND (S/N: BFM1-UP)
C11 INDUSTRIAL (S/N: GLS1-UP)
C13 INDUSTRIAL (S/N: LGK1-UP)
C15 IND (S/N: JRE1-UP)
C15 INDUSTRIAL (S/N: JAS1-UP)
C27 INDUSTRIAL (S/N: TWM1-UP)
C32 INDUSTRIAL (S/N: TLD1-UP)
C9 INDUSTRIAL (S/N: JSC1-UP; MBD1-UP; JLW1-UP)
Petroleum Engine:
C-15 PETROLEUM (S/N: Z2C1-UP)
C32 PETROLEUM (S/N: SMP1-UP)
Truck Engines:
C7 TRUCK ENGINE (S/N: NPH1-UP; LBM1-UP)
C7 TRUCK/BUS (S/N: YPG1-UP)
C9 ON-HIGHWAY (S/N: ETK1-UP)
Excavator:
325D (S/N: KHX1-UP)
330D (S/N: THX1-UP)
345C (S/N: MHX1-UP)
365C (S/N: LHX1-UP)
385C (S/N: RHX1-UP)
Track Feller Buncher:
TK752 (S/N: 4ZF1-UP)
Load Haul Dump:
R1700G (S/N: RSX1-UP)
Mobile Hydraulic Power Unit:
330C MHPU (S/N: SAN1-UP)
Transmission:
TH31-E61 (S/N: SKY1-UP)
Off-Highway Truck/Tractor:
773F (S/N: EHX1-UP)
777F (S/N: LJW1-UP)
Quarry Truck:
775F (S/N: LJX1-UP)
Power Module:
C18 POWER MODUL (S/N: X6X1-UP)
C32 POWER MODUL (S/N: MED1-UP)
Track-Type Loader:
973C (S/N: THY1-UP)
Pumper:All Utility Mounted
Introduction
This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a
parts reusability program. Reuse and salvage information enables Caterpillar Dealers and customers to benefit
from cost reductions. Every effort has been made in order to provide the most current information that is
known to Caterpillar. Continuing improvement and advancement of product design might have caused changes
to your product which are not included in this publication. This Reuse and Salvage Guideline must be used
with the latest technical information that is available from Caterpillar.
For additional information about this guideline, consult Repair Process Engineering of the Marketing &
Product Support Division at 1 (309) 675-5434.
Summary
A used crankshaft must be checked for the out of round, wear of the thrust face, the profile and the surface
finish. If the crankshaft is ground undersize, the radius and hardness of the journal must also be checked.
Crankshafts with an undersize dimension must be checked for straightness. Used crankshafts must also be
checked for straightness.
This guideline gives the procedure for measuring crankshafts and straightening crankshafts. If a crankshaft
meets the specifications that are found in this guideline, the crankshaft can be expected to give normal
performance until the next overhaul when the crankshaft is used again in the same application.
Some bent crankshafts can be used again if the crankshaft is straightened. Measuring the crankshaft carefully
is the first step in the salvage procedure.
Refer to Reuse and Salvage Guideline, SEBF8041, "Crankshaft Specifications" for the measurements of a
crankshaft. The crankshaft may be used again if the measurements are met.
References
ReferenceRefer to Reuse and Salvage Guideline, SEBF8039, "Inspection of Crankshafts for Cracks".
ReferenceRefer to Reuse and Salvage Guideline, SEBF8041, "Specifications for Crankshafts in Caterpillar
Engines".
ReferenceRefer to Reuse and Salvage Guideline, SEBF8042, "Procedure to Grind and Polish Crankshafts".
ReferenceRefer to Reuse and Salvage Guideline, SEBF8043, "Visual Inspection of Crankshafts".
ReferenceRefer to Reuse and Salvage Guideline, SEBF8156, "Procedure to Inspect Crankshafts in 3500
Family of Engines".
Tooling and Equipment

Table 1
Tooling and Equipment

Part Number Part Description
8T-5096 Dial Indicator Test Group
5P-4163 Indicator Contact Point
5P-8637 Crankshaft Support (vee blocks)
6V-7926 Dial Indicator Group
7B-0337 Surface Plate
6V-6035 Hardness Tester
7H-1940 Universal Attachment
3P-1568 Dial Indicator
7H-1941 Dial Indicator Base
7H-1948 Swivel Post
- Radius Gauges
When replacement parts are required for this product Caterpillar

recommends using Caterpillar replacement parts or parts with
equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product

damage, personal injury or death.
Crankshaft Inspection
Perform the following checks in order to confirm the reusability of the crankshaft.
Note: Refer to Reuse and Salvage Guideline, SEBF8039, "Inspection of Crankshafts for Cracks" and Reuse
and Salvage Guideline, SEBF8043, "Visual Inspection of Crankshafts" for crankshaft inspection.
The following visual checks must be initially performed. These checks will determine if the crankshaft is
reusable early in the process without wasting valuable time.
1. Examine all surfaces of the crankshaft for discoloration which has been caused by excessive heat. Do
not reuse any parts that have been removed from an engine which was involved in a fire.
2. Examine the exterior surfaces of the crankshaft for physical damage such as nicks, dents, large cracks,
etc.
3. Examine the connecting rod and the main bearing journals for deep scratches, cracks in the fillets, the
transfer of metal due to lack of lubrication, or evidence of damage due to improper grounding during
welding.
4. Examine all surfaces of the crankshaft for discoloration. Any crankshaft that has been excessively hot
should not be reused.
5. Check for signs of rust and corrosion.
6. The crankshaft must be correct for the intended engine application. The crankshaft must also be a
genuine Caterpillar product.
Grinding the bearing surfaces is one method that is used to straighten bent crankshafts. This method is limited,
because the bearing surfaces must be completely ground. The finished size must not be smaller than the next
available undersize bearing. In addition, it is much easier to grind after the crankshaft has been straightened.
Caterpillar recommends straightening all crankshafts before grinding.
Note: Crankshafts that have been reground for marine engines are not approved by some marine certification
societies and by some insurance companies. Contact the insurance company or a representative from the
marine certification society for acceptability of crankshafts that have been reground.
Procedure to Measure Used Crankshafts for Bend

Tooling Setup
Illustration 1 g01364775
6V-7926 Dial Indicator Group
1. Use the 6V-7926 Dial Indicator Group for all measurements.
(1) The vee blocks need to be positioned underneath the main journal bearings at the end of the crankshaft.
Use the 5P-8637 Vee Blocks under the main journals at the end of the crankshaft in order to support the crankshaft.
2. Put two 5P-8637 Vee Blocks on the surface plate or a concrete floor. Do not use a work bench. The
weight of the crankshaft may bend the work bench which causes errors in the measurements.
Note: The vee blocks should be aligned before the crankshaft has been placed on top and after the
crankshaft has been placed on top. Align the vee blocks so that both bases are an equal distance from an
established reference point. A secured metal strip that is parallel to the edge of a surface plate or a blue
line reference on concrete are good reference points.
3. Support the crankshaft with the vee blocks under the main journals on the end of the crankshaft. Check
the blocks and the crankshaft in order to ensure that the blocks and the crankshaft are stationary and
aligned. The crankshaft must rotate in the vee blocks, but the crankshaft must not move horizontally.
Note: Ensure that the oil hole does not come in contact with the center of the vee block. When possible,
keep the vee block to one side of the crankshaft journal but not into the fillet. The diameter of the
crankshaft journal should be the only point of contact with the vee block.
The dial indicator's magnetic base needs to be held stationary with a piece of steel with three pads welded to the bottom.
4. Use a piece of steel to hold the magnetic base for the indicator. Spread apart three pads at 120 degrees
and weld the pads to the bottom of a piece of steel.
Note: Use the same reference point in Step 2 to align the base of the indicator. This will ensure a more
efficient procedure for setup and inspection.
(1) The vee blocks need to be positioned under the main journal bearings on the end of the crankshaft.
5. Place the stem of the dial indicator on the piece of steel. Put the contact point for the dial indicator on
one of the two main journals that are next to a vee block. Refer to Illustration 4. Position the dial
indicator so the stem will not contact the oil hole. The contact point must be perpendicular to the bearing
surface.
6. Once the adjustments are made, rotate the crankshaft at 360 degrees in order to ensure that the travel of
the dial indicator is sufficient. Adjust the dial indicator to zero.
Note: This procedure must be performed when the vee blocks have been moved.
Procedure for Performing the Measurement
(A) Main bearing journal
(B) Main bearing journal
(1) Position the vee blocks under the main journals on the end of the crankshaft.
Note: Assume that the tooling was set up on the main journal (A) .
1. Rotate the crankshaft at 360 degrees and record the Total Indicated Readout (TIR). The TIR is the
difference between the highest readings and the lowest readings on the dial indicator while the
crankshaft is being rotated.
Note: If an oil hole comes in contact with the vee block, the TIR will be incorrect. Try to keep the vee
block to one side of the crankshaft journal, but not into the fillet, so that the diameter of the crankshaft
journal is the only point of contact with the vee block.
2. Move the dial indicator to the other main bearing journal (B) next to a vee block. Rotate the crankshaft
at 360 degrees and record the TIR.
(2) Vee blocks positioned under the main journals in the center of the crankshaft.
3. Move each vee block toward the center of the crankshaft one main bearing journal. Refer to Illustration
6.
(C) Take the next measurement from this position.
(2) Vee blocks positioned under the main journals in the center of the crankshaft.
4. Measure the next main bearing journals that are located inside the vee blocks. The next main bearing
journals should also be closest to the vee blocks. Refer to Illustration 7 (C) .
Measure the center main bearing journal.
5. Continue the procedure until the main bearing journal at the center of the crankshaft is measured. Refer
to Illustration 8.
Note: If there are two maximum points during the measurement of TIR, use an outside micrometer. Check for
an out of round main journal. If an oil hole comes in contact with the vee block, the TIR will be incorrect.
Refer to Reuse and Salvage Guideline, SEBF8041, "Specifications for Crankshafts in Caterpillar Engines" for
all specifications of crankshafts.
(3) Pilot hub for flywheel
(4) Flange face for flywheel
(5) Flange for flywheel
(6) Main bearing journals
(7) Flange for pulley, gear or damper
(8) Straight shaft or tapered shaft
(9) Flange face for pulley or damper
(10) Pilot hub for damper
Procedure to Measure Crankshafts after the Bearing Journals have

been Ground
If a crankshaft is reground, journals must be in alignment with other surfaces of the crankshaft. The TIR for
any of the measurements that follow cannot be more than specifications shown in Reuse and Salvage
Guideline, SEBF8041, "Specifications for Crankshafts in Caterpillar Engines". The crankshaft cannot be used
again if the measurements are greater. Grind the crankshaft to the next standard size and then measure the
crankshaft again when it is possible.
Measurement of TIR on Hub Circumference or Flange for Flywheel
Measuring the circumference of the flange for the flywheel
1. Put vee blocks under the front and rear main bearing journals. Put the contact point of the dial indicator
on the circumference of the flywheel pilot. Refer to Illustration 10.
Note: The contact point must not be in the wear groove of the rear crankshaft seal.
Measuring TIR of the flywheel
2. The contact point must be perpendicular to the surface and at the approximate centerline of the
crankshaft. For all engines with a pilot hub for the flywheel, put the contact point for the dial indicator
on the hub of the crankshaft. This is shown in Illustration 11.
Note: The pilot hub on a crankshaft can be a lot shorter than the pilot hub that is shown in Illustration
11. Refer to Reuse and Salvage Guideline, SEBF8041, "Specifications for Crankshafts in Caterpillar
Engines".
3. Turn the crankshaft 360 degrees and check TIR.
Measurement of TIR on Flange for Pulley or Damper and Flywheel
The measurement of the flange face for a puller or a damper on a lathe. The measurement can also be made with vee blocks, a
hardened steel ball, and a heavy object.
Refer to ""Preventing Axial Movement of the Crankshaft" " section of this guideline. Remove the 5P-4163
Indicator Contact Point . Install the 7H-1940 Universal Attachment to the dial indicator. Put the point for the
universal attachment on the face of the flange for the pulley or the damper. This is shown in Illustration 14.
The point of the universal attachment must be near the outer circumference of the flange face so that the point
will not hit the holes in the crankshaft. Turn the crankshaft 360 degrees and check TIR. Use the same
procedure for the face of the flywheel flange.
Measurement of TIR on Main Bearing Journals

Measure the main bearing journals. This is shown in ""Procedure to Measure Used Crankshafts for Bend" "
section of this guideline. The maximum TIR specifications for the main bearing journals of any reground
crankshaft is 0.13 mm (0.005 inch).
Measurement of TIR on Front Flange, Straight Front Shaft or Hub

Circumference
Perform the steps outlined under ""Measurement of TIR on Hub Circumference or Flange for Flywheel" "
section of this guideline in order to check the TIR on the front flange, the straight front shaft, or the hub
circumference. The contact point must be perpendicular to the surface and at the approximate centerline of the
crankshaft. Turn the crankshaft 360 degrees and check TIR. Do not allow the contact point to hit a keyway.
Measurement of TIR on Tapered Front Shaft
Measuring the tapered surface
Refer to ""Preventing Axial Movement of the Crankshaft" " section of this guideline. Put the contact point for
the dial indicator near the end of the tapered surface. This is shown in Illustration 13. The contact point must
be perpendicular to the tapered surface and at the approximate centerline of the crankshaft. Turn the crankshaft
360 degrees and check TIR. Do not allow the contact point to hit a keyway.
Preventing Axial Movement of the Crankshaft

The remainder of the measurements can be done with accuracy only if any axial movement of the crankshaft is
prevented. One method is installing smaller crankshafts and medium crankshafts on a lathe in the center of the
crankshaft.
Note: Do not use a lathe to check TIR of the main bearing journals of a large crankshaft. The weight of the
crankshaft can cause an incorrect TIR.
Crankshaft with a steel ball that is pushed against a heavy steel object
A second method is by using vee blocks with a hardened steel ball that has the diameter of 19.7 to 22.4 mm
(0.62 to 0.88 inch). Put the steel ball in a machined center on the front end of a crankshaft. Push the crankshaft
and the steel ball against a heavy steel object. This is shown in Illustration 14. Do not move or dent the heavy
steel object when pressure is applied. The crankshaft must be held against the steel object while the
measurements are taken. Put oil on the steel ball.
Determine if a Bent Crankshaft Can Be Straightened

Follow this procedure to measure the overall TIR at the center main bearing.
The crankshaft is installed on vee blocks. Measure the TIR at the center main journal bearing only. This will determine if the
crankshaft can be straightened safely.
1. Perform steps 1 through 4 of ""Tooling Setup" " section of this guideline.
2. Place the contact point for the dial indicator on the center main bearing. Refer to Illustration 15. The
contact point must be to the side of the oil hole, perpendicular to the bearing surface, and at the
approximate centerline of the crankshaft.
3. Rotate the crankshaft to 360 degrees after the adjustments have been made. Moving the crankshaft
ensures that there is sufficient travel for the dial indicator. Adjust the dial indicator to zero.
4. Turn the crankshaft 360 degrees and check the dial indicator. Make a note of TIR.
5. The crankshaft can be straightened if TIR is within the specifications found in Reuse and Salvage
Guideline, SEBF8041, "Crankshaft Specifications".
Straightening a Bent Crankshaft

Equipment Needed to Straighten Bent Crankshafts
Oven
Heating the crankshaft with an oven is crucial. The oven must heat the crankshaft to 117 to 232°C (350 to 450°
F). To prevent cracks, do not straighten the crankshaft at room temperature. Temperature of the crankshaft can
be measured with a 164-3310 Infrared Thermometer . The temperature can also be checked with temperature
recording crayons.
Hydraulic Press for Straightening
A hydraulic press is necessary to straighten the crankshaft. The press must be equipped with one or more dial
indicators to measure TIR on the main bearing journals while the crankshaft is in the press.
Hydraulic presses are available from the following corporations.
Eitel Presses Inc.

97 Pinedale Industrial Road
Orwigsburg, PA 17961
http://www.eitelpresses.com/
Phone: 570 366 0585 Fax: 570 366 2536
Dake Corporation
724 Robbins Rad
Grand Haven, MI 49417
http://www.dakecorp.com/
Phone: 800 937 3253Fax: 800 846 3253
NOTICE
In order to prevent damage to the crankshaft, the anvil and the ram
must be made from soft steel or copper. When you straighten a
crankshaft do not use vee blocks as supports. The use of an anvil or a
ram that is wider than the bearing journal can cause damage to the
fillet.
Equipment for Magnetic Particle Inspection
A crankshaft that has been straightened must be checked for cracks. The magnetic particle inspection must be
used after straightening the crankshaft.
Refer to Reuse and Salvage Guideline, SEBF8039, "Inspection of the Crankshafts for Cracks".
Machine for Shot Peening
Shot peening the fillet of the bearing journal on some crankshafts may be necessary. This procedure must be
done after the crankshaft has been straightened. Refer to Reuse and Salvage Guideline, SEBF8041,
"Crankshaft Specifications" and Reuse and Salvage Guideline, SEBF8042, "Procedure To Grind and Polish
Crankshafts".
Procedure to Straighten Bent Crankshafts

1. Heat the crankshaft in the oven for a minimum of 1 1/2 hours. Do not use a torch. Using a torch does not
produce an even heat. One part of the crankshaft may become too hot and other parts may not get hot
enough. Straighten the crankshaft when the temperature is between 117°C to 232°C (243°F to 450°F).
2. Put anvils on each side of the main journal that will be straightened. Check for burrs on the anvil and the
surfaces of the ram.
3. Turn the crankshaft so that the ram can make contact at the high point. Put a dial indicator in position in
order to measure the deflection of the crankshaft.
4. Carefully put the ram against the main journal that will be straightened.
5. Put a small amount of pressure on the crankshaft and release the ram. The deflection during this step
must not be more than one half of the TIR measured in ""Procedure to Measure Used Crankshafts for
Bend" " section of this guideline.
6. Check the straightness of the crankshaft. Put the contact point for the dial indicator against the main
bearing journals. The contact points must be to the side of the oil holes. Turn the crankshaft and look at
the dial indicator. Apply more pressure and increase the deflection if the TIR on the main bearing
journals next to the vee blocks is more than 0.13 mm (0.005 inch). The TIR for 3406 engines must be
more than 0.18 mm (0.007 inch). After increasing the deflection, measure the TIR again.
7. Increase the amount of pressure in small increments, until the TIR on this journal is less than 0.13 mm
(0.005 inch). Be careful not to use too much pressure since excessive pressure can cause the crankshaft
to bend in the opposite direction. Cracks will occur if the crankshaft is bent in the opposite direction.
8. Repeat step 3 through 6 in order to straighten any other bent areas on the crankshaft.
9. Measure the amount of bend in the crankshaft according to the directions in ""Procedure to Measure
Used Crankshafts for Bend" " section of this guideline.
10. Check the crankshaft for cracks. Especially check the fillets of the journal on the opposite side of the
ram. Use the magnetic particle inspection. Refer to Reuse and Salvage Guideline, SEBF8039,
"Inspection of Crankshafts for Cracks".
Crankshaft Measurement
Preparing for Crankshaft Measurement
A crankshaft installed on two 5P-8637 Vee Blocks .
Place the crankshaft on two 5P-8637 Vee Blocks . The blocks should be on a sturdy work surface in order to
hold the crankshaft during the following procedures. Refer to Illustration 16. Use an outside micrometer with a
vernier scale and a friction thimble for taking measurements. The micrometer must have a graduation of 0.001
mm (0.0001 inch).
Note: For greatest accuracy, use a gauge block to adjust the micrometer before each crankshaft is checked.
Procedure to Check Surface Finish
Analyzing the surface finish
Note: A sclerometer should not be used on any remanufactured crankshaft that has Melonited Heat Treat
(MHT) stamped next to the 0R part number. The use of this instrument will damage the crankshaft.
The surface finish of bearing journals should be checked with a powered surface finish analyzer that will
stroke the journal automatically. Refer to Illustration 17. The radius of the stylus must be approximately 0.013
mm (0.0005 inch) and the unit should have a 0.80 mm (0.0315 inch) cut off length.
Note: The maximum permissible surface roughness for bearing journals is given in Reuse and Salvage
Guideline, SEBF8041, "Specifications for Crankshafts in Caterpillar Engines".
Polish the journals if the surface roughness does not meet the specifications. Refer to Reuse and Salvage
Guideline, SEBF8042, "Procedure to Grind and Polish Crankshafts".
The surface finish of the thrust face must be at least 0.45 mm (0.018 inch). Ensure that no wear steps or marks
occur from grinding on the surface. Refer to Reuse and Salvage Guideline, SEBF8043, "Visual Inspection of
Crankshafts".
Surface Finish Analyzers
Surface finish analyzers are available from several companies.
Taylor Hobson Ltd

PO Box 36
2 New Star Road
Leicester, LE4 9JQ, England
www.taylor-hobson.com
Phone: 44 (0) 116 276 3771Fax: 44 (0) 116 246 0579
Mitutoyo Manufacturing Co.

965 Corporate Blvd.
Aurora, IL 60502
www.mitutoyo.com
Phone: 630-820-9666Fax: 630-820-2614
Procedure to Check for Out Of Round and Diameter
Measuring for out of round of the journal diameter
Use an outside micrometer to measure the journal diameter at top dead center TDC. Measure 90 degrees from
TDC on rod journals and also at two places 90 degrees from on the main journals. Refer to Illustration 18. Be
sure to keep the anvil of the micrometer out of the oil hole and the immediate area around the oil hole that the
journal surface is lower.
The dimensions must be no greater than the specifications in Reuse and Salvage Guideline, SEBF8041,
"Specifications for Crankshafts in Caterpillar Engines". The diameter of two rod journals can be 0.005 mm
(0.0002 inch) under the minimum specifications that are shown in Reuse and Salvage Guideline, SEBF8041,
"Specifications for Crankshafts in Caterpillar Engines".
Note: If the crankshaft has been ground undersize, subtract the undersize dimension of the crankshaft from the
minimum or maximum dimensions. Refer to Reuse and Salvage Guideline, SEBF8041, "Specifications for
Crankshafts in Caterpillar Engines" for the correct dimensions.
Procedure to Check for Taper
Taking the measurement on one side of the journal
Measure the diameter of the rod journal at TDC next to each fillet but not on the fillets. Measurements must be
taken on both sides of the journal. Refer to Illustration 19. The difference of the two measurements may not
exceed the dimensions of taper. Refer to Reuse and Salvage Guideline, SEBF8041, "Specifications for
Crankshafts in Caterpillar Engines" for specifications of taper.
Example
The diameter of the main bearing journal of a 2P-2842 Crankshaft on a 3306 Engine
Table 2
3306 Crankshaft
One fillet
88.890 mm (3.4996 inch)
Other fillet
88.877 mm (3.4991 inch)
Difference
0.013 mm (0.0005 inch)
The difference is less than the reusable specification of 0.015 mm (0.0006 inch) for maximum taper. The
journal has acceptable taper.
Procedure to Check for Wear of the Thrust Face
Measuring the wear of the thrust face with a micrometer
Measure the distance between the thrust surfaces. Use an inside micrometer. Refer to Illustration 20. The
measurement between the thrust faces must be between the maximum and the minimum reusable
specifications.
Note: When the crankshaft is installed, check for the correct crankshaft end play. Refer to the appropriate
Reuse and Salvage Guideline.
Procedure to Measure Profile
Measuring the profile of the crankshaft
Follow this procedure when specific measurements of profile are necessary. The following tooling is required
for this test. Refer to Illustration 21.
Table 3
Tooling for Measuring Profile
3P-1568 Dial Indicator or a similar indicator with the accuracy of
0.002 mm (0.0001 inch)

7H-1941 Dial Indicator Base and 7H-1948 Swivel Post Snug
Both parts are included in the 8S-2328 Dial Indicator Group .

7B-0337 Surface Plate
5P-8637 Vee Blocks
1. Put the vee blocks on a concrete floor or a sturdy surface. Put the crankshaft on the vee blocks. Put a
surface plate under the journal that will be measured.
2. Adjust the dial indicator so the contact point will slide against the top of the journal that will be
measured.
3. Adjust the dial indicator to zero at the highest point of the journal diameter. Move the dial indicator base
on the surface plate in order to stroke the journal diameter horizontally at intervals of 3 mm (0.1 inch).
Refer to Illustration 21.
25 mm (1 inch) horizontal is equivalent to the dial indicator reading of 5.08 mm (0.200 inch). 25 mm (1 inch) vertical is
equivalent to the dial indicator reading of 0.003 mm (0.0001 inch).
4. Mark the location of each maximum indication reading on graph paper. When all the readings are taken,
connect the points on the graph paper. This is shown in Illustration 22.
The graph is acceptable because all points are within the width of 0.005 mm (0.0002 inch).
5. Place a second sheet of graph paper over the original piece in order to check that all the points are within
the width of 0.005 mm (0.0002 inch). Refer to Illustration 23. If any points are outside this width, do not
use the crankshaft again unless the crankshaft has been ground.
The crankshaft is installed between centers on a lathe. A 3P-1568 Dial Indicator is mounted on the tool holder.
Specific measurements of profile can be taken by using both procedures. The procedures are very similar. The
difference is placing the crankshafts on the centers of a lathe instead of vee blocks. A 3P-1568 Dial Indicator is
mounted on the tool holder. The contact point is then adjusted in order to slide against the main journal or the
rod journal horizontally at 3.0 mm (0.12 inch) intervals. Refer to Illustration 24. Repeat the procedure in step 4
and 5.
Equipment needed to Measure the Profile
Several other companies make equipment for measuring the profile.
Taylor Hobson Ltd

PO Box 36
2 New Star Road
Leicester, LE4 9JQ, England
www.taylor-hobson.com
Phone: 44 (0) 116 276 3771Fax: 44 (0) 116 246 0579
Procedure to Check the Fillet of the Journal

There are two procedures for checking the radius of the fillet. Using the correct size of gauges is the preferred
method. Use the bracket check method if the correct gauges are not available.
Procedure to Check Radius with Correct Gauge
Follow this procedure to check the fillet of the journal after the crankshaft has been ground.
1. Use a decimal radius gauge with a range of 2 to 20 mm (0.095 to 0.75 inch). Compare the profile of the
radius gauge with the profile of the fillet. If the radius gauge matches the fillet, there will be no space
between the two. Refer to Illustration 26. A radius gauge in fractions can be used after the fractions are
accurately converted to the decimal or metric equivalents.
Radius gauges are available from several companies.
Starrett
www.starrett.com
Phone: (978) 249-3551Fax: (978) 249-8495
1. Put the correct size of radius gauge into the fillet. The radius gauge must come into contact with the
center of the radius.
Measuring the radius of the fillet
The gauge is the correct size because the entire gauge is in contact with the radius of the fillet.
The radius is too large. The nose of the gauge is the only part of the gauge that contacts the fillet.
The radius is too small. The gauge is contacting the radius at the shoulders of the gauge.
2. The radius of the crankshaft must meet the specifications in Reuse and Salvage Guideline, SEBF8041,
"Specifications for Crankshafts in Caterpillar Engines" in order to be reused.
Note: The Reuse and Salvage Guideline, SEBF8041, "Specifications for Crankshafts in Caterpillar Engines"
contains dimensions of radii before the peening operation. When possible, measure the fillets before the
peening operation. Refer to Reuse and Salvage Guideline, SEBF8043, "Visual Inspection of Crankshafts" for
information.
Procedure for Bracket Checking the Radii of the Journal Fillet
The bracket check should be used when the exact gauges can not be found. It will be necessary to measure the
radius of the fillet by using other gauges that have a larger radius and smaller radius than the specified fillet.
Refer to the following example.
1. Use a gauge that is smaller than the radius of the fillet. The nose of the gauge should contact the contour
of the fillet. Refer to Illustration 27. If the shoulders of the gauge contact the fillet, then the gauge is
larger than the fillet.
2. Use a gauge that is larger than the radius of the fillet. The nose of the gauge should not contact the
contour of the fillet. Refer to Illustration 27. If the nose of the gauge contacts the fillet, the gauge is
smaller than the fillet.
3. The bracket check method should show that the radius of the fillet is between the gauges. The crankshaft
will give normal performance if the selected gauges are close to the specified radius of the fillet. The
crankshafts must also meet the other physical requirements.
Special Checking Procedure for Specific Crankshafts

The following information is used to check the radius of the rod and the main fillet. This information is only
used for 1W-0400, 0R-5560, 0R-5474, AND 0R-5164 crankshaft.
Checking the radius of the rod
(9) Max Point of Tangency with Sidewall
(10) Typical Profile
The profile of the fillet must fall within Zones (A, B, and C) .
The minimum radius in Zone (C) is 0.76 mm (0.030 inch).
The minimum radius in Zone (B) is 4.88 mm (0.192 inch).
The minimum radius in Zone (A) is 0.76 mm (0.030 inch). Double fillet intersection may occur in Zone (A). The intersection may
contain a sharp peak. Refer to item (10) .
Checking the radius of the main fillet
(9) Max Point of Tangency with Sidewall
(10) Typical Profile
The profile of the fillet must fall within Zones (A, B, and C) .
The minimum radius in Zone (C) is 0.76 mm (0.030 inch).
The minimum radius in Zone (B) is 2.34 mm (0.092 inch).
The minimum radius in Zone (A) is 0.76 mm (0.030 inch). Double fillet intersection may occur in Zone (A). The intersection may
contain a sharp peak. Refer to the Typical Profile.
Procedure to Check the Hardness of the Journal

If a journal shows signs of high heat or grinding, check the hardness of journal. A sclerometer such as the 6V-
6035 Hardness Tester can be used. Only use a sclerometer since other methods may damage the crankshaft.
Refer to Illustration 31.
Follow the manufacturer's recommendations for use of the sclerometers such as the 6V-6035 Hardness Tester .
Refer to Reuse and Salvage Guideline, SEBF8041, "Specifications for Crankshafts in Caterpillar Engines" for
tolerances of hardness. The readings from the sclerometer must be within these tolerances.
Note: A soft spot may be found on a journal. Check both sides of the soft area if this occurs. If the hardness of
the journal is within the specifications on both sides of the soft area then the harness of the journal is
acceptable.
Important
On crankshafts such as the Series 3208 and Series 3300 families of engines, the rear half of the rear main
journal and the rear fillet can be softer than the specifications of Reuse and Salvage Guideline, SEBF8041,
"Specifications for Crankshafts in Caterpillar Engines".
Checking hardness with a sclerometer
Note: A Sclerometer should not be used on any remanufactured crankshaft that has Melonited Heat Treat
(MHT) stamped next to the 0R part number. The use of this instrument will damage the crankshaft.
Copyright 1993 - 2008 Caterpillar Inc. Wed Jun 18 13:34:36 EST 2008
Todos los derechos reservados.
Red privada para licenciados del SIS.

Procedure To Measure and Straighten Bent Crankshaft PDF

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3306 Industrial Engine 64Z05381-UP(SEBP1989 - 24) - Estructura del documento Página 1 de 26

Producto: ENGINE - MACHINE

Pautas de reutilización y recuperación

Procedure to Measure and Straighten Bent Crankshafts{1202}

C9 GEN SET (S/N: C9E1-UP)

ReferenceRefer to Reuse and Salvage Guideline, SEBF8043, "Visual Inspection of Crankshafts".

Tooling and Equipment

Tooling and Equipment

When replacement parts are required for this product Caterpillar

Failure to heed this warning can lead to premature failures, product

5. Check for signs of rust and corrosion.

Procedure to Measure Used Crankshafts for Bend

1. Use the 6V-7926 Dial Indicator Group for all measurements.

Procedure for Performing the Measurement

(B) Main bearing journal

(3) Pilot hub for flywheel

(4) Flange face for flywheel

(5) Flange for flywheel

(6) Main bearing journals

(7) Flange for pulley, gear or damper

(8) Straight shaft or tapered shaft

(9) Flange face for pulley or damper

(10) Pilot hub for damper

Procedure to Measure Crankshafts after the Bearing Journals have

Measurement of TIR on Hub Circumference or Flange for Flywheel

Measuring TIR of the flywheel

3. Turn the crankshaft 360 degrees and check TIR.

Measurement of TIR on Flange for Pulley or Damper and Flywheel

Measurement of TIR on Main Bearing Journals

Measurement of TIR on Front Flange, Straight Front Shaft or Hub

Measurement of TIR on Tapered Front Shaft

Preventing Axial Movement of the Crankshaft

measurements are taken. Put oil on the steel ball.

Determine if a Bent Crankshaft Can Be Straightened

1. Perform steps 1 through 4 of ""Tooling Setup" " section of this guideline.

Straightening a Bent Crankshaft

Hydraulic Press for Straightening

Hydraulic presses are available from the following corporations.

Eitel Presses Inc.

Equipment for Magnetic Particle Inspection

Machine for Shot Peening

Procedure to Straighten Bent Crankshafts

Procedure to Check Surface Finish

Surface Finish Analyzers

Surface finish analyzers are available from several companies.

Taylor Hobson Ltd

Mitutoyo Manufacturing Co.

Procedure to Check for Out Of Round and Diameter

Procedure to Check for Taper

Procedure to Check for Wear of the Thrust Face

Procedure to Measure Profile

Tooling for Measuring Profile

3P-1568 Dial Indicator or a similar indicator with the accuracy of

0.002 mm (0.0001 inch)

Both parts are included in the 8S-2328 Dial Indicator Group .

Equipment needed to Measure the Profile

Several other companies make equipment for measuring the profile.

Taylor Hobson Ltd

Procedure to Check the Fillet of the Journal

Procedure to Check Radius with Correct Gauge

Radius gauges are available from several companies.

Procedure for Bracket Checking the Radii of the Journal Fillet

Special Checking Procedure for Specific Crankshafts