SEBF8043 Crankshaft Visual Inspection

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Reuse And Salvage Guidelines

Visual Inspection of Crankshafts
Media Number -SEBF8043-03 Publication Date -26/10/2004 Date Updated -27/10/2004
SEBF80430001
Visual Inspection of Crankshafts

SMCS - 1218
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE
CAT®
OPERATIONS
SEBF8043-03
SMCS Code: 1202
Visual Inspection of Crankshafts September
2004
Summary of Revisions
Page Description
All Revised format.
Added step information for the 3412
9
Crankshaft
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
https://198.101.139.4:8443/sisweb/servlet/cat.dcs.sis.controller.techdoc.CSSISFormatTe... 8/1/2006
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) 494-1934.
Summary
Many times, a visual inspection will determine if a crankshaft, that looks damaged, can be used
again after reconditioning. This Guideline gives the criteria for this type of visual inspection.
If a crankshaft is within the specifications shown in this Guideline and other Guidelines, 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 cannot be used again. Correct any
conditions that could have caused the need for reconditioning.
Glossary
Blend: To machine smoothly

Intersection: Junction
Embedded: Pushed into a surface
Depressions: Marks caused by shot peening
Smearing: Deposits of bearing material
Raised: A higher level
Reground: Machined to a smaller dimension
References
References
Form No. Title
SEBF8020 Wear Sleeves for Shafts
SEBF8039 Inspection of Crankshafts for Cracks
SEBF8041 Specifications for Crankshafts in
Caterpillar Engines
SEBF8042 Procedure to Grind and Polish
Crankshafts
SEBF8054 Procedure to Straighten and Measure
Bent Crankshafts
SEBF8156 Procedure to Inspect Crankshafts in
3500 Family of Engines
SMHS6959 Installing Wear Sleeves and Crankshaft
Seals Using 9S-8868, 9S-8873, 9S-
8891, and
9S-8888 Tooling Group
Tooling and Equipment
Tooling and Equipment1

Part No. Description
1F1160 Cold Chisel
1P-3075 Lip Seal Puller

9S-9081 Sling Assembly
6V-2010 Polishing Stone
6V-3184 Brush Group
1 Refer to the latest version of NENG2500 Tools and Shop Products Guide , for any changes.
Nomenclature
Illustration 1
Nomenclature
General Information
When a crankshaft is removed, installed, or moved, be very careful not to damage journals. When
possible, use the 9S-9081 Sling Assembly or two 1.5 m (5 ft) nylon slings with a capacity of 675 Kg
(1500 lb). See Illustration 2.
Illustration 2
Nylon slings used to lift crankshaft.
Put slings into position around two main or rod journals equal distance from the ends of crankshaft.
Make certain nothing metallic comes in contact with bearing journal surfaces, fillets, or other
important machined areas.
If crankshaft is lifted by any other method, some type of protection (thick rubber hose, plastic tubes,
or soft brass) must be put at the point of contact with the journals. These protective materials must
be checked regularly for signs of wear and/or embedded metal particles.
Before Visual Inspection
1. Immediately after crankshaft has been removed from the engine, look for any clear signs of
heavy damage that cannot be corrected by reconditioning.
2. Clean the outside of crankshaft with a high pressure wash, steam, solvent, vapor degreaser, or
caustic bath and rinse.
3. If crankshaft cannot be inspected immediately (less than one hour after it is cleaned), coat
journals with a layer of engine oil to prevent corrosion.
After Visual Inspection
Specific instructions for the following steps are found in "Procedures to Clean Oil Passages" and
"Storage Procedures" in this Guideline.
1. All Allen head plugs must be removed and oil passages thoroughly cleaned.
2. All lightening hole core plugs must be removed and oil passages thoroughly cleaned.
3. The crankshaft must be prepared for storage.
Visual Inspections
Journal Surface
Illustration 3
Typical example of broken and/or cracked crankshafts.
Do not use again
Illustration 4
Do not use again
Illustration 5
Do not use again
Use the following crankshafts only if journal hardness is acceptable and if there is enough material
on journal surface to grind it undersize. For procedures to check the hardness and journal
dimensions, see Guideline for Reusable Parts SEBF8054 "Procedure to Measure and Straighten
Bent Crankshafts" and SEBF8041 Specifications for Crankshafts in Caterpillar Engines .
Illustration 6
Journals show signs of heat and moved material.
Do not use again
Illustration 7
Do not use again
Illustration 8
Do not use again
The following crankshafts can be used again after the journal is polished and only if the profile and
surface finish are acceptable. For measurement of profile and surface finish, see Guideline for
Reusable Parts SEBF8054 "Procedure to Measure and Straighten Bent Crankshafts" and SEBF8041
Specifications for Crankshafts in Caterpillar Engines .
Illustration 9
Example of lightly scratched bearing journals.
Do not use again
Illustration 10
Do not use again
Illustration 11
Do not use again
Illustration 12 shows a journal which has been scratched. Use again if scratch is 0.5 mm (0.020
inch) or less in width, is not in a fillet, and does not go through the oil hole. Remove all burrs with a
6V-2010 Polishing Stone and then polish journal. After journal is polished, the crankshaft must
meet specifications in Guideline for Reusable Parts SEBF8041 Specifications for Crankshafts in
Caterpillar Engines .
Illustration 12
Journal has a single heavy scratch on its circumference.
Do not use again
Illustrations 13 and 14 show dents and scratches on journal. Use again only if dent (or scratch) is
shorter than half the journal width, does not go beyond the bearing width (as shown in Illustration
14), or does not go into a fillet. Remove burrs with a 6V-2010 Polishing Stone and then polish the
journal.
NOTICE
Do not use the 6V2010 polishing stone to remove

defect, but only to remove the burrs or any raised
edges.
Illustration 13
Small dent on rod journal.
Do not use again
Illustration 14
Deep scratch on rod journal goes beyond the bearing width.
Do not use again
Journals with smearing can be used again after journal is polished and all smearing is removed.
Illustration 15
Typical example of smearing.
Do not use again
Illustration 16
Typical example of smearing.
Do not use again
Crankshaft journals with a wear step that can be seen and felt or that measures more than 0.005 mm
(0.0002 inch) must be ground to an acceptable profile. See Guideline for Reusable Parts SEBF8054
"Procedure to Measure and Straighten Bent Crankshafts".
On 3412 crankshafts, it is acceptable to grind the rod journals using a double plunge process,
where each half of a given rod journal is independently ground. The dimensions of this wear step
cannot exceed a maximum height of 0.0177 mm (0.0007 inch) or a maximum width of 0.89 mm
(0.035 Inch). Other than this ground step feature, all normal surface finish requirements apply. See
Guideline for Reusable Parts SEBF8042 Procedure to Grind and Polish Crankshafts .
NOTE: As long as the step resulting from the double plunge grinding process meets these
requirements, it is in no way detrimental to the performance or durability of the crankshaft.
Illustration 17
Wear steps that can be seen and felt on journal surface.
Do not use again
Illustration 18
Wear steps that can be seen and felt on journal surface.
Do Not Use Again
Illustration 19
Ground step on a 3412 connecting rod journal
Use again
Provided the maximum height of 0.0177 mm (0.0007 Inch) and the maximum width of 0.89 mm
(0.035 Inch) is not exceeded.
Use crankshafts with evidence of erosion only after journal is polished and the corrosion completely
removed. If pitting remains after journal is polished, grind journal undersize.
Illustration 20
Typical example of corrosion.
Do not use again
Illustration 21
Typical example of corrosion.
Do not use again
Illustration 22
Water marks on the journal surface. Use again only after journal is polished and measured.
Do not use again
Illustration 23
Water marks on journal surface. Use again only after journal is polished and measured.
Do not use again
Illustration 24
Normal number of depressions on bearing journal surface and a normal number of depressions in
fillet.
Do not use again -
if there is a high concentration of depressions on bearing journal surface.
Use again
as is or if there is a very small number of depressions on bearing journal surface.
Illustration 25
Signs of chatter on bearing journal surface. Use again only if the chatter can no longer be seen after
journal is polished. If chatter remains, crankshaft must be reground.
Do not use again
Illustration 26
A journal surface that did not "clean up" completely after it was ground. The journal surface must be
ground to next undersize journal diameter and "clean up" completely around journal circumference.
Do not use again
Journals with embedded metal particles as seen in Illustration 26 can be used again after journal
surface is polished, and if all embedded metal particles and burrs are removed. Measure journal. If
it is not acceptable, journal must be reground.
Illustration 27
Embedded metal particles (and burrs) on journal bearing surface.
Do not use again
Oil Hole
Oil holes with sharp edges can be used again after sharp edges are removed and the oil holes are
polished. Oil holes with debris in the oil hole should be thoroughly flushed of all debris. See
"Procedure to Clean Oil Passages"
Illustration 28
Oil holes have sharp edges.
Do not use again
Illustration 29
Oils holes have sharp edges.
Do not use again
Illustration 30
Debris in oil hole.
Do not use again
Fillet
Illustration 31
Signs of bearing material in fillet. Use again after fillet is polished and all bearing material is
removed.
Do not use again
Illustration 32
Scalloping in main journal fillet.
Use again
Illustration 33
Scalloping in rod journal fillet.
Do not use again
Illustration 34
Example of pitting in fillet. Use again only if all pitting is removed by grinding or polishing.
Do not use again
Illustration 35
Example of pitting in fillet. Use again only if all pitting is removed by grinding or polishing.
Do not use again
Illustration 36
After journal has been reground, there may be a change in contour (shape) low in the fillet.
Do not use again -
unless changes in the contour are above the point shown in Illustration 36. Make sure fillet blends
smoothly with the journal surface.
Illustration 37
Blending the fillet into the journal surface.
Illustration 38
Example of fillets that did not "clean-up" when ground. Fillet must "clean up" as shown in
Illustration 36.
Do not use again
Illustration 39
Example of fillets that did not "clean-up" when ground. Fillet must "clean up" as shown in
Illustration 36.
Do not use again
Illustration 40
Fillet shown signs of heat. Use again only if journal hardness is acceptable according to Guideline
For Reusable Parts SEBF8041, "Crankshaft Measurement".
Do not use again
Sidewall
Illustration 41
Wear step that is more than 0.12 mm (.005 in) located in sidewall. Use again only if wear step is
less than 0.12 mm (.0005 in) and sidewall is ground smooth.
Do not use again
Illustration 42
Damage to sidewall. Use again after raised material is removed and sidewall is smooth.
Do not use again
Illustration 43
Oil and carbon deposits on sidewall. Use again after sidewall is polished and deposits are removed.
Do not use again
Illustration 44
Scratch on sidewall. Use again after burrs are removed with the 6V-2010 Polishing Stone, and
sidewall is polished.
Do not use again
Illustration 45
Damage goes into the rod journal sidewall surface.
Do not use again
Grinder burns on the journal or in the fillet are

NEVER permitted.
Use the following crankshafts only after it has been thoroughly inspected according to Guideline For
Reusable Parts SEBF8039 "Inspection of Crankshafts For Cracks".
Illustration 46
Typical grinder burns on the sidewall.
Do not use again
Illustration 47
Typical grinder burns on the sidewall.
Do not use again
Illustration 48
Typical grinder burns on sidewall.
Do not use again
Thrust Face
Illustration 49
Wear step in thrust face. For thrust face dimension, see Guideline For Reusable Parts SEBF8041
"Crankshaft Measurement".
Use again -
if wear step is outside thrust bearing surface and dimension is acceptable and if wear step is in thrust
wear surface, can be ground out, and dimension is acceptable.
Illustration 50
Corrosion on thrust face. Use again after thrust face is polished and all corrosion is removed.
Do not use again
Illustration 51
Smearing on thrust face. Use again only after thrust face is polished and all bearing material is
removed.
Do not use again
Illustrations 52 and 53 show grinder burns on thrust surface. Use again if no open or closed
indications are found when inspected, according to Guideline For Reusable Parts SEBF8039
"Inspection of Crankshafts for Cracks".
Illustration 52
Grinder burns in thrust face surface.
Do not use again
Illustration 53
Grinder burns in thrust face surface.
Do not use again
If thrust face is damaged as shown in Illustration 54, use crankshaft only if wear step can be ground
clean and thrust dimension meets specifications in Guideline For Reusable Parts SEBF8041
Specifications for Crankshafts in Caterpillar Engines .
Illustration 54
Thrust face damaged by grinding wheel.
Do not use again
Web and Counterweight
Crankshafts with counterweight damage can be used again after rough edges are made smooth with a
hand grinder and the area is checked for indications according to Guideline For Reusable Part
SEBF8039 "Inspection of Crankshafts for Cracks".
Illustration 55
Counterweight damage.
Do not use again
NOTICE
If too much material or small pieces of

counterweight are removed, check balance.
Lightening Hole
Illustration 56
Very fine crack in lightening hole.
Do not use again
Keyway
Illustration 57
Keyway groove has rough, sharp edges. Use again after rough and/or raised edges are completely
removed with a small file or emery paper.
Do not use again
Tapered Shaft
Illustration 58
Burrs on tapered shaft. Use again after burrs are removed with a 6V-2010 Polishing Stone.
Do not use again
Gear
Illustration 59
Gears have broken teeth and/or show heavy pitting.
Do not use again
Illustration 60
Gears have broken teeth and/or show heavy pitting.
Do not use again
Seal Surface
Damaged seal surfaces can be reconditioned by installing a wear sleeve over the groove, or, if
possible, installing the seal to one side of the wear. For wear sleeve installation, see Guideline For
Reusable Parts SEBF8020, "Wear Sleeves for Shafts" and Special Instruction, SMHS6959.
Illustration 61
A groove along the circumference of the seal surface can be easily felt.
Do not use again
Illustration 62
A groove along the circumference of the seal surface can be easily felt.
Do not use again
Illustration 63
The oil thrower surface on 6.25 inch bore engines must be free of scratches, burrs or grooves.
Use again
Plug Removal
Removal and Installation of

Allen Head Plugs
Plugs must be removed and oil passages must be thoroughly cleaned after visual inspection and any
necessary reconditioning operations have been made.
To remove Allen Plugs:
1. Use a 10.0 mm (.39 in) drill to remove peened (bent) metal around the plug.
Note: If plug cannot be removed easily with the use of a 3/16 inch Allen Wrench, drill through plug
with a 6.0 mm (.25 in) drill and remove it with a 1/4 inch easy-out-remover.
2. After oil passage has been cleaned, (see "Procedure to Clean Oil Passages") install plug and
tighten to a torque of 23 ± 4 N·m (204 ± 36.0 lb in).
3. Fasten plug using a punch to stake (cause distortion) the web in three places.
Later 6.25 inch bore V-Engines use a special self-locking bolt with a hexagon socket head instead of
the Allen Plug. This bolt can be removed with a 3/8 inch Allen Wrench. After the oil passage has
been cleaned, install self-locking bolt and tighten to a torque of 47.5 ± 7.0 N·m (420.0 ± 60.0 lb in).
Removal and Installation of Lightening Hole Core Plugs
To remove lightening hole core plugs:
1. Remove the snap ring with two screwdrivers, or cut snap ring in half with a sharp 1F-1160 Cold
Chisel.
Note: Some snap rings can be removed with pliers or snap ring pliers. Regardless of the method, be
careful not to damage snap ring groove or bore.
2. Remove plug with a 1P-3075 Lip Seal Puller. Make a small hole a little off center of the plug
for easier removal.
3. Clean oil passages.
4. Install new core plugs. If snap ring was twisted or cut during removal, install a new one. Make
sure new snap ring is fitted correctly in the snap ring groove. See Chart A for correct drivers and
sleeves needed for plug and snap ring installation.
Note: On earlier 6.25 Bore V-Engines, 8L-9802 Plugs are used in the lightening holes. If, for any
reason, these plugs were never installed, install new 8L-9802 Plugs after the oil passages have been
cleaned.
Chart A.
Drivers and Sleeves for Core Plug Installation
Model Driver Sleeve
619C and 824 Tractor Engines; FT0128 FT0129
D326, D337, D343, and D336
Engines in all applications
641, 650, 651, 657, 660, and FT0130 FT0131
666 Tractor Engines
D353, D379 and D398 Engines FT0132 FT0133
in all applications
Procedure to Clean Oil Passages
Use a 6V-3184 Brush Group and solvent to clean oil passages (Illustration 63). See Chart B for
correct brush diameter.
Illustration 64
Use 6V-3184 Brush Group to thoroughly clean oil passages.
Install the brush on a variable speed drill. Operate

the drill at 300 rpm. Never operate the drill unless
the brush is inside the oil passage.
Chart B.
Brush Diameters
Model or Bore Size 8 mm 11 mm
(.31 in) (.44 in)
1100 and 3100 Series, 3208 X
3204 X
D311, D315, D318 X
D320, D330, D330C, D333, X X
D333C, D334, D346, D348,
D349, D353, 3304, 3306, 1673,
1673C, 1674
D336, D342, D343, 1676, X X
1693, 5.4" Bore 90 V8, 5.75"
Bore 4 Cyl.
D379, D398, D399 X X
3406, 3408, 3412 X X
It is important that oil passages be thoroughly cleaned. The brush must go all way to the end of each
oil hole. To do this, all oil holes must be cleaned from every possible angle: from both the rod and
main journal ends and from the lightening hole or plug end of the oil hole. To make sure oil
passages are kept free of debris, flush all passages with solvent during procedure to clean. After the
oil passages are thoroughly cleaned, use an air hose to remove remainder of the solvent.
Storage Procedures
Protection of the crankshaft from corrosion is very important. Corrosion will start within one hour
after the crankshaft has been cleaned. If the storage period is expected to be less than three months,
coat the crankshaft with a layer of engine oil, including inside the oil holes. If a longer period of
storage is desired, follow recommendations in Chart C.
Chart C. Storage Recommendations

Rust Inhibitor Manufacturer
3 Months to 1 Year
SAFECOTE A Daubert Chemical Company
1200 Jorie Blvd. Oak Brook
IL, 60521 USA
RUST VETO HWF E.F. Houghton & Company
303 West Lehigh Avenue
Philadelphia PA, 19133 USA
DW 7-6-T Detrex Chemical Industries,,
Inc. P.O. Box 501-TR
Detroit MI, 48232 USA
1 Year To 2 Years
PDRD Sprayon Products, Inc.
PENETRANT RUST 26302 Fargo Ave.
PREVENTATIVE Bedford Heights OH, 44146
707 USA
Over 2 Years
NOX-RUST 110 Daubert Chemical Company
1200 Jorie Blvd.
Oak Brook IL, 60521 USA
For long periods of storage, put a thin layer of rust inhibitor on crankshaft and keep it in a wooden
box (Illustration 64).
Damage other than corrosion can also be a problem during storage. For extended periods of storage
put plastic plugs in all oil holes and heavily oiled cardboard between all journals and rack supports.
Illustration 65
Store crankshafts in a wooden box.
Note: The crankshaft and oil passages must be thoroughly cleaned after storage and before
installation.
Notes:
SEBF8043-03 CATERPILLAR® ©2003 Caterpillar
Copyright 1993 - 2006 Caterpillar Inc. Tue Aug 1 08:03:06 UTC+0700 2006
All Rights Reserved.
Private Network For SIS Licensees.

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3516B Generator Set GAR00001-UP(SEBP3938 - 09)/Basic Search Page 1 of 49

Product: GENERATOR SET

Reuse And Salvage Guidelines

Visual Inspection of Crankshafts

Blend: To machine smoothly

Tooling and Equipment

Tooling and Equipment1

1P-3075 Lip Seal Puller

Nylon slings used to lift crankshaft.

Before Visual Inspection

After Visual Inspection

"Storage Procedures" in this Guideline.

3. The crankshaft must be prepared for storage.

Typical example of broken and/or cracked crankshafts.

Do not use again

Typical example of broken and/or cracked crankshafts.

Do not use again

Typical example of broken and/or cracked crankshafts.

Do not use again

Journals show signs of heat and moved material.

Do not use again

Journals show signs of heat and moved material.

Do not use again

Journals show signs of heat and moved material.

Do not use again

Example of lightly scratched bearing journals.

Do not use again

Example of lightly scratched bearing journals.

Do not use again

Example of lightly scratched bearing journals.

Do not use again

Journal has a single heavy scratch on its circumference.

Do not use again

Do not use the 6V2010 polishing stone to remove

Do not use again

Do not use again

Typical example of smearing.

Do not use again

Typical example of smearing.

Do not use again

Do not use again

Do Not Use Again

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again -

if there is a high concentration of depressions on bearing journal surface.

as is or if there is a very small number of depressions on bearing journal surface.

journal is polished. If chatter remains, crankshaft must be reground.

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again

Do not use again -

Do not use again

Do not use again

Do not use again