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Reuse And Salvage Guidelines


Inspection of Crankshafts for Cracks
Media Number -SEBF8039-01 Publication Date -24/09/2002 Date Updated -25/09/2002

SEBF80390001

Inspection of Crankshafts for Cracks


SMCS - 1202

SEBF8039-01
March 2001
SMCS Code: 1202

GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
Inspection of Crankshafts for Cracks
Summary of Revisions

Page Description

All Revised format.

Introduction
This guideline enables dealers and their customers to benefit from cost reductions made possible through an established parts reusability
and salvage program. Every effort has been made to provide the most current and relevant information known to Caterpillar Inc. Since the
Company makes ongoing changes and improvements to its products, this guideline must be used with the latest technical information
available from Caterpillar to ensure such changes and improvements are incorporated where applicable.

For questions or additional information concerning this guideline, contact Caterpillar Service Support Division, Dealer Support (309) 675-
5156.

Summary
This guideline gives visual procedures to show the differences between the most common types "cracks" in crankshafts. The type of
"crack" is very important because crankshaft reconditioning is possible with some types of "cracks" but is not possible with other types.
Until positive identification of the type of crack is made, all visual signs of cracks are known as "indications".

If a crankshaft meets these guidelines for cracks, it can be expected to give normal performance until the next overhaul when used again
in the same application.

Never use a crankshaft that this guideline shows can not be used again. During reconditioning, correct any conditions that could have
caused the cracks.

Note: Crankshafts can meet the Caterpillar specifications in this guideline but not meet the requirements of some marine
societies (for example, Lloyd s of London, and the American Bureau of Shipping). In some cases, marine societies do not
permit use of a crankshaft showing ANY indication under ultraviolet magnetic particle inspection.

Glossary
Longitudinal: In the direction parallel to
the centerline of the

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crankshaft.
Magnetize: The application of electric
current to make a
crankshaft a magnet.
Ultraviolet: High frequency light.
Indication: The general name for
what looks like a crack,
including a real crack,
during magnetic particle
inspection.

Nomenclature

Illustration 1

Illustration 2

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Illustration 3

Illustration 4

Equipment Needed to Inspect Crankshafts for Cracks


Crankshafts must be inspected by the magnetic particle method. A special machine is necessary for this procedure. It must be an
alternating current (AC) "wet" type of machine (one that uses oil with magnetic particles that can be seen under ultraviolet light).
Illustration 5 shows one of a number of machines available (see page 45 for a list of manufacturers).

The machine must be large enough to hold all crankshafts that are normally inspected. It must be equipped with a cover over the top and
an exhaust fan to remove fumes released from the oil solution.

A 100" (2540 mm) machine is long enough to hold all current and non-current Caterpillar crankshafts except the one used in the D399
Engine which is 2578 mm (101.5 inch) in length. If necessary, most machines can be adapted to hold the crankshaft for the D399 Engine
(Illustration 6). Contact manufacturers for more information on this.

Be sure the machine can magnetize the crankshaft through the use of end contacts and a magnetizing coil. The coil must have a
minimum inside diameter of 20" (508 mm). See Illustration 7.

The oil for the solution must not be seen under ultraviolet light. Follow the manufacturer s recommendations to mix the magnetic particles
into the oil. (For Magnaflux machines, use 4.73 grams (0.17 oz) of No. 14A dry "Magnaglo" concentrate per gallon of "Magnaglo" oil.) Be
sure the solution is thoroughly mixed by the pump. Use a long brush to mix the particles that are in the tank each time the machine is to
be used. The solution must be changed every three months or when it looks dirty. Check its concentration every day. See Illustration 8.

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Illustration 5

Typical machine used to find cracks in crankshafts.

Illustration 6

Testing unit adapted to hold crankshaft from D399 Engine.

Illustration 7

Magnetizing coil installed on testing unit.

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Illustration 8

Concentration of Magnaglo" solution must be .20 to .40 cc of magnetic particles (after 30 minutes) per 100 cc of solution.

Procedure to Find Cracks


1. Clean the outside of the crankshaft with a solvent, vapor degreaser, high pressure washer or steam. Do this off the machine to keep
the solution clean.
2. Use the correct V-blocks (not shown), rests (Illustrations 9 and 10), or rollers
(Illustration 11) so the crankshaft is level, rotation is possible, and the magnetizing coil can move along the crankshaft without
contact with the webs. For smaller crankshafts use the Magnaflux No. 156970 Adjustable Rail Mounted Steadyrest (not shown) or
similar support so there is no contact with the webs during crankshaft rotation.
3. Install the crankshaft so the contact pads make good contact with both ends. Use braided copper pads (Magnaflux No. 1846D) to
stop sparks (Illustration 12).

Follow the manufacturer s instructions


carefully for installation of the
crankshaft on the machine.

Illustration 9

Rest installed on testing unit.

Illustration 10

Crankshaft installed on rest.

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Illustration 11

Typical example of roller.

Illustration 12

Copper pad installed.

NOTICE

Be very careful if it is necessary to use a


spacer with either end of the crankshaft
(Illustration 13). When inspection is
complete, check the ends of the
crankshaft for damage from sparks,
especially on the flywheel hub area.

Illustration 13

Use of a spacer to make contact with the end of the crankshaft.

4. Adjust the controls on the machine for the correct current (Illustration 14). Se the chart for longitudinal current recommendations.

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Illustration 14

Controls for current setting.

Recommendations for Longitudinal Currents

Main Journal
Current (Amperes)
Diameter Time

Up to 90 mm (3.500 2 seconds
1500
inch) minimum*

Up to 90 mm (3.500 3 seconds
2000
inch) minimum*

* The Crankshaft must not become warm.

5. Be sure the solution is thoroughly mixed and the concentration is correct.


6. Put the solution along the complete length of the crankshaft (Illustration15) and immediately turn on the current while the solution
drains.

Illustration 15

Application of solution to the crankshaft.

Do not make contact with the machine


or the crankshaft while the current is on.
Follow the machine manufacturer s
safety instructions carefully.

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Illustration 16

Longitudinal current is best to find indications that are parallel to the centerline of the crankshaft. (The indication shown is not a crack.)

7. Inspect the crankshaft for cracks. The inspection will show best those indications which are longitudinal. (Illustration 16).
8. Change the controls to put the current through the magnetizing coil (Illustration 17). See the chart for coil current recommendations.

Illustration 17
Magnetizing coil in place over crankshaft.

Recommendations for Coil Currents

Main Bearing
Current (Amperes)
Diameter Time

Up to 90 mm (3.500 2 seconds
2500
inch) minimum*

Up to 90 mm (3.500 3 seconds
3000
inch) minimum*

* The Crankshaft must not become warm.

9. During this part of the inspection, magnetize one main journal and two connecting rod journals, or two main journals and one
connecting rod journal at one time. (Illustration 18). On smaller crankshafts, it is possible to magnetize more journals at one time.
Turn on the current while the solution drains.

Illustration 18

Application of solution on area to be checked.

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10.
11. Inspect the crankshaft for cracks. This inspection will show best those indications that go around the journal circumference.
(Illustration 19).

Illustration 19

The magnetizing coil is best to find indications which go around the crankshaft journal.

12.
13. Use instructions given by the machine s manufacturer to remove magnetism. The magnetic level must be less than 5 Gauss. (Use
a Magnetic Field Indicator, like No. 2480 from Magnaflux Corporation. The indicator needle must move more than one point from
zero on this indicator. Move the indicator around both ends of the crankshaft to get a reading). See Illustration 20.
14. Clean the crankshaft thoroughly in solvent to remove the inspection solution particles.
15. Put a layer of oil on the crankshaft for protection. Do this off the machine.

Illustration 20

Use of a magnetic field indicator to measure magnetism.

General Information for Inspection


Generally, during reconditioning a crankshaft needs several inspections for cracks. For example, a first inspection can show fine journal
cracks caused by heat; after the area is ground, a second inspection can show if these same cracks were ground out. It is a good practice
to inspect for cracks after any operation to straighten, grind or polish a crankshaft (that is, before installation) to find if all cracks are gone.
Look carefully along the complete crankshaft for indications. Look especially at oil holes on journals and in all fillets.

Types of Indications
"Indication" is the general name for what LOOKS like a crack, including a real crack, during magnetic particle inspection. Correct
identification of the type of indication is very important. There are four types of indications.

Open Indications

Open indications can be seen without the inspection solution or can be felt with a fingernail. See Illustrations 21 and 22. If an open
indication is found to be a crack and does not grind out, the crankshaft can not be used again. Other open indications are permitted if they
are not in the red "CRITICAL" areas of the crankshaft (see chart on page 14 for location of "CRITICAL" areas). Open indications can be
real cracks, but they can also be the result of differences in the steel, pitting, heavy scratches or grooves. See Illustrations 23 and 24.

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Illustration 21

Typical example of an open indication as seen with the inspection solution and an ultraviolet light.

Illustration 22

The same open indication without the inspection solution and with normal light.

Illustration 23

Example of an open indication as seen with inspection solution and an ultraviolet light.

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Illustration 24

Same open indication without the inspection solution and with normal light.

Scratches can show as open indications under magnetic inspection, but they can normally be checked with a magnifying glass. Scratches
are usually shiny at the bottom of the groove. Use an optical comparator or inspection microscope to measure the width of an open
indication when a maximum size is given in the specifications.

Note: Remove the inspection solution before you use the comparator. When necessary, use a magnifier of 10 to 50 times
magnification to give more detail. Illustration 25 shows the 6V-2196 Microscope. It has a magnification of 20 times.

Illustration 25

Inspection microscope in use.

Closed Indications

Closed indications are not easily seen without the inspection solution and cannot be felt with a fingernail. See Illustrations 26 and 27. They
can be caused by differences in the steel or by material in the steel or under its surface. In general, a crankshaft can be used again if the
closed indications are not in the red "CRITICAL" areas and are less than 28 mm (1.12 inch) long if on a journal surface. See chart on page
14 for location of "CRITICAL" areas).

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Illustration 26
Closed indication can be seen with inspection solution.

Illustration 27
Without inspection solution, closed indication cannot be seen.

False Indications

False indications are caused by dirt, rust or the wrong mixture of the inspection solution. Some are caused by the use of too much current
during inspection. When an indication looks false, clean the area with a cloth and make a second inspection. False indications do not
come back.

Cracks

Normally, a crack can be seen with or without inspection solution. Cracks have rougher edges than other types of indications. See
Illustrations 28 and 29. Cracks are normally continuous; that is they are constant and not broken. SOME SMALL CRACKS ON
JOURNALS (CAUSED BY HEAT) CAN BE GROUND OUT. OTHER CRACKS ARE NEVER PERMITTED IN ANY AREA OF THE
CRANKSHAFT.

Illustration 28

Typical example of crack, as seen with the inspection solution and ultraviolet light.

Illustration 29

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Without the inspection solution, the rough edges of a crack can be seen in regular light, with a magnifying glass or microscope.

Note: Be careful at points where the crankshaft changes shape suddenly to prevent an error in identification of a crack.
Illustrations 30 and 31 show how indications can, at times, be seen in rough areas. Similar indications can be seen where two
surfaces meet or at the junction of the machined surface of a journal sidewall and the web area.

Illustration 30

Illustration 31

Typical rough area which can look like a crack.

Also, check very carefully because some indications will not be clear or not show completely in just a longitudinal or a coil check. See
Illustrations 32 and 33.

Illustration 32

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Illustration 33

Illustration 32 and 33 show the same indication with and without inspection solution.

Important Areas to Inspect


In the illustrations that follow, specific areas are shown in different colors according to their importance. Use the chart as a reference for
the color codes used in the illustrations.

Area Color Typical Locations General Rules

CRITICAL Red "CRITICAL" fillet areas; No indications are permitted.


Oil holes in journals;
Around ends of keyways;
Inside lightening holes.

IMPORTANT Yellow "IMPORTANT" fillet No open indications are


areas. permitted.

"IMPORTANT" web No obvious (easily seen in


areas (section between regular light) open
rod and main journal indications are permitted.
centerlines).

SECONDARY Green Majority of journal No cracks are permitted after


surfaces; grinding and polishing. All
Most machined shaft other indications up to 1.12"
surfaces (front and rear by .006" (28 mm by .15 mm)
shafts). are permitted.

OTHER White Majority of web areas; No cracks are permitted.


Threaded areas at front Most pother indications are
and rear of older permitted.
crankshafts.

Fillet and Journal


Sidewall Areas
In Illustrations 34 through 40, "CRITICAL" fillet and journal sidewall areas are shown in red. "IMPORTANT" fillet and journal sidewall areas
are shown in yellow.

Note: See the section "Journal and Oil Hole Areas" for more information about "CRITICAL" journal oil hole areas.

Do not use a crankshaft again that has any indication in a "CRITICAL" fillet or journal sidewall area.

Do not use a crankshaft again that has any open indications in an "IMPORTANT" fillet or journal sidewall area.

Remember, the "CRITICAL" fillet area is where the crankshaft is thinnest. This area is either 90° or 180° of the circumference according to
the size of the crankshaft.

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NOTICE

Inspect for cracks in the fillet areas


before any shot peening operation. Shot
peening can prevent small fillet cracks
from being seen.

Crankshafts with fillet radii greater than 5.23 mm (0.206 inch).

Illustration 34

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Illustration 35

Crankshafts with fillet radii less than 5.23 mm (0.206 inch).

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Illustration 36

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Illustration 37

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Illustration 38

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Illustration 39

Illustration 40

Indication through fillet area.

Do not use again

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Illustration 41

Illustration 42

Indications in fillet area.

Do not use again

Illustration 43

Indication along the circumference at the junction of fillet and journal is a crack.

Do not use again

Do not use a crankshaft with a crack that goes into the fillet area, even if it cannot be seen after the crankshaft is ground.

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Illustration 44

Illustration 45

Be sure that fine indications are not false indications. Do not grind out fillet cracks, even if they look very fine.

Do not use again

Illustration 46

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Illustration 47

Fine cracks in fillet between two rod journals on crankshaft from 3408 Engine.

Do not use again

Journal and Oil Hole Areas


In Illustration 48 journal and oil hole "CRITICAL" AREAS ARE SHOWN IN RED. "SECONDARY" areas are shown in green.

Note: See the section, "Fillet And Journal Sidewall Areas" for information about "IMPORTANT" areas on journals near the
fillets.

Do not use a crankshaft again that has any indications in an oil hole "CRITICAL" area.

Open indications up to 28 mm long by 0.15 mm wide (1.12 in long by 0.006 in wide) are permitted in the green "SECONDARY" areas; all
closed indications are permitted in the green "SECONDARY" areas.

Illustration 48

The 3.1 mm (0.12 in) dimension outside the chamfer must be 9.6 mm (0.38 in) for connecting rod journal oil holes if the flashline is in line with the oil hole. (Examples: D339, D342, D353, D399 Engines; see page 29).

Illustration 49

Crack in oil hole.

Do not use again

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Illustration 50

Illustration 51

Fine indications in oil holes.

Do not use again

Illustration 52

Small cracks less than 3.0 mm (0.12 in) from the chamfer area.

Do not use again

Grind the crankshaft to the next journal size, then polish. Use again unless there are indications less than 3.0 mm (0.12 in) from the
chamfer area. There must be no cracks.

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Illustration 53

The open indication is not a crack (edges are not rough and it is very fine) and is not in the chamfer area.

Use again

Illustration 54
Indications are very fine, straight and shorter than 28 mm (1.12 in). These indications are not cracks; the edges are not rough. If they are scratches, remove any edges that are above the surface with a 6V-2010 Arkansas
Polishing Stone or 6V83 4/0 Emery Polishing Paper and solvent before final polish.

Use again

Illustration 55
Indications are very fine, and total length is less than 28 mm (1.12 in). This indication is not a crack (there are no rough edges, and the indication is fine and straight). When indications are broken, like this example, they
are not cracks but differences in the steel.

Use again

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Illustration 56

These closed indications can not be seen or felt with the oil removed, but length of total indication is more than 28 mm (1.12 in). Also, the right indication has a fork (two branches).

Do not use again

Use again if all indications are gone after the crankshaft is ground.

Illustration 57

Illustration 58

Several long, closed, parallel indications that are not cracks, Illustration 58 shows that they can not be seen in regular light.

Do not use again

Use again if there are less than five closed indications and they are all shorter than 28 mm (1.12 in) in length, or if the indications can be
ground out at a smaller journal diameter. Do not use again if there are open cracks.

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Illustration 59

The oil hole in the connecting rod journal is in line with the flash line in some D339, D342, D353 and D399 Engines.

For the above engines only:

Use again ⎯
if closed indications along flash line are less than .25"
(6.3 mm) long and not in the oil hole area

Do not use again ⎯


if open indication is along flash line

Illustration 60

Illustration 61

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Illustration 62

Illustration 63

Note: Illustrations 60, 61, 62 and 63 show types of small cracks caused by heat. Cracks can be longitudinal, around the
circumference, twisted or connected.
USE AGAIN ONLY IF ALL CRACKS ARE GONE AFTER THE JOURNALS ARE GROUND TO A SMALLER DIAMETER.

NOTICE

Check all journals for hardness after


they are ground. See guideline For
Reusable Parts, SEBF8041, for more
information.

Illustration 64

Three larger cracks will not grind out.

Do not use again

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Illustration 65

Cracks still there after a journal was ground to a smaller diameter.

Do not use again

Illustration 66

Fine indication (not a crack and no rough edges) is still there after the crankshaft is ground, in an area where there were no indications before grinding. (It is not in a "CRITICAL" area and journal hardness is correct. The
indication is less than 28 mm (1.12 in) long.)

Use again

Illustration 67

The ends of the horizontal crack area at a 45° angle to the centerline of the crankshaft. Many times, short horizontal indications at the center of the journal are cracks, so check very carefully.

Do not use again

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Illustration 68

Crack is about 25 mm (1.0 in) from the oil hole and parallel to the centerline of the crankshaft. Many times, horizontal indications about 25 mm (1.0 in) from an oil hole are cracks, so check very carefully.

Do not use again

Illustration 69

Journal indications are connected and will not grind out. (Most indications on journals that are connected are cracks.

Do not use again

Web Areas

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Illustration 70

The "IMPORTANT" area between the centerline of the main and connecting rod journals is the area between the dotted lines.

In Illustration 70, "CRITICAL" web areas are shown in red. "IMPORTANT" web areas are shown in yellow.

Note: See Pages 15-21 for information on fillet and journal sidewall areas that are machined.

Do not use a crankshaft again that has ANY indications in a "CRITICAL" web area (lightening holes).
Do not use a crankshaft again that has an obvious (easily seen in regular light) open indication or crack in the "IMPORTANT" web area
between the centerlines of the main and connecting rod journals. Fine and closed indications in this web area are permissible.

Illustration 71

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Illustration 72
Indications or groups of indications in web areas are normal unless they go into a lightening hole or go into a machined journal sidewall surface more than .040" (1.0 mm).

Use again

Illustration 73

Indication goes into a machined journal sidewall area more than 1.0 mm (0.040 in).

Do not use again

Illustration 74

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Illustration 75

Indications or cracks in lightening hole area.

Do not use again

Illustration 76

Illustration 77

Indications in web does not go into the lightening hole or a machined journal sidewall surface. Indications in web can be open indications if caused by a change in the surface.

Use again

Note: If desired, use a small grinder to remove any indications in webs, but make sure the edges are smooth and grind only
deep enough to remove the indication.

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Illustration 78

Illustration 79

Long indication in web area is only on the surface and does not go into a machined journal sidewall surface more than 1.0 mm (0.040 in).

Use again

Illustration 80

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Illustration 81

Indication goes into groove made to drill oil hole.

Use again

Illustration 82

Illustration 83

There can be several indications and they can be any shape. They must not go more than .040" (1.0 mm) into a machined journal sidewall surface.

Use again

Illustration 84

Indication goes around corner, but area is in the counterweight away from any machined journal sidewall surface.

Use again

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Illustration 85

Illustration 86

Open indication in web is very deep and cannot be removed unless it is ground more than 3.0 mm (0.12 in) deep.

Do not use again

Illustration 87

Large area where indication was ground out; make sure any sharp edges are smooth.

Use again

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Illustration 88

Illustration 89

Illustration 90

Illustration 91

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Some indications can be seen in several webs. These indications normally follow the shape of the crankshaft or the flashline.

Use again unless the indications go more than 1.0 mm (0.040 in) into a machined journal sidewall surface or there are obvious (easily
seen in regular light) open cracks.

Use again

Flange, Shaft and


Keyway Areas
In Illustrations 92 through 99 "CRITICAL" areas are
shown in red. "IMPORTANT areas are shown in yellow.

Illustration 92

Illustration 93

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Illustration 94

Illustration 95 and Illustration 96

Illustration 97

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Illustration 98

Illustration 99

Threaded shafts.

Note: Fine cracks on the front edge A of a keyway at the front of a threaded type of shaft are permitted.

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Illustration 100

Illustration 101

1) Crack in area where gear is located.


2) Cracks at end of keyway.

Do not use again

Suppliers of Magnetic Particle Testing Equipment


Note: Not all of the manufacturers that follow have machines that can hold the larger Caterpillar crankshafts.

MAGNAFLUX CORPORATION
7300 W. Lawrence Avenue
Chicago, Illinois 60565 U.S.A.
Telephone: (312) 867-8000
Telex: 25-4194 (for information about offices
outside the United States.)

Leasing service for Magnaflux equipment:


Industrial Leasing Corporation
2300 S. W. Sixth Avenue
Portland, Oregon 97201 U.S.A.
Telephone: (800) 547-4905 or (503) 228-2111

Note: Magnaflux also has offices in New York, Pittsburgh, Cleveland, Detroit, Dallas, and Los Angeles. Training courses on
equipment operation are available.

ECONOSPECT CORPORATION
1757 Tanen Street
Napa, California 94558 U.S.A.
Telephone: (707) 226-9833

HANCO INTERNATIONAL
Division of Hannon Electric Co.
Canton, Ohio 44707 U.S.A.
Telephone: (216) 456-4728

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Cable: HANCO
TWX: (810) 432-9058

HANCO INTERNATIONAL EUROPA N.V.


P.O. Box 137
Amstelveen, Holland
Cable: NOCONI

HANCO INTERNATIONAL AUSTRALIA PTY LTD


Chin Chen Street
Islington (New Castle), 2N, N.S.W. 2296, Australia

URESCO
10603 Midway Avenue
Cerritos, California 90701, U.S.A.
Telephone: (213) 773-3828
TWX: (910) 583-4950

KWIK-WAY MAUNFACTURING COMPANY


500 57th Street
Marion, Iowa, 52302, U.S.A.
Telephone: (319) 377-9421
Telex: 464461 KWIKWAY MARW

Copyright 1993 - 2005 Caterpillar Inc. Tue Oct 25 00:39:20 EST 2005
All Rights Reserved.
Private Network For SIS Licensees.

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