SEBF8042 Grind Crankshaft

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Reuse And Salvage Guidelines

Procedure to Grind and Polish Crankshafts
Media Number -SEBF8042-08 Publication Date -01/09/2004 Date Updated -01/09/2004
SEBF80420001

SMCS - 1202
CATERPILLAR®
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
https://tu-tc-nt2:8443/sisweb/servlet/cat.dcs.sis.controller.techdoc.CSSISFormatTechDocForPrintServlet?... 7/12/2006
Summary of Revisions
Page Description
All Revised format.
All Combined information from SEBF8094
and SEBF8103 with this publication.
11 Added Double Plunge grinding a
3412 Crankshaft.
References
References
Form No. Title
NENG2500 Tools and Shop Products Guide
SEHS7949 Crankshaft Inspection Form
Inspection of Crankshafts for
SEBF8039
Cracks
Specifications for Crankshafts in
SEBF8041
Caterpillar Engines
SEBF8043 Visual Inspection of Crankshafts
Procedure to Measure and
SEBF8054
Straighten Bent Crankshafts
Procedure to Inspect Crankshafts in
SEBF8156
3500 Family of Engines
Equipment and Tooling
Equipment and Tooling1

Part No. Description
Grinding Machine
6V-6035 Hardness Tester
Electric high speed polisher
6V-3044 Polishing Belt
6V-3184 Brush Group
1 Refer to the latest version of NENG2500 Tools and Shop Products Guide , for any changes.
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) 494-1934.
Summary
Many worn or damaged crankshafts can be used again after they are ground and/or polished. This guideline gives the
procedures for grinding and polishing Caterpillar crankshafts. Whenever a crankshaft is reground, it must be checked
for straightness, journal surface finish, cracks, hardness, fillet radius, taper, out-of-round, profile, thrust face wear and
surface finish, journal diameter and width dimensions.
Crankshafts that have been reground and are acceptable according to Caterpillar specifications published in Guideline
for Reusable Parts and Salvage Operations, SEBF8041, Specifications for Crankshafts in Caterpillar Engines are
not necessarily acceptable to some insurance companies and marine societies.
If a crankshaft is ground and polished according to this guideline and if it is inspected according to other Guidelines for
Reusable Parts and Salvage Operations on crankshafts, it can be expected to give normal performance until the next
overhaul when used again in the same application.
Never install a part that this guideline shows cannot be used again. During reconditioning, correct any conditions that
might have caused the original failure.
Illustration 1
Crankshaft Inspection Form SEHS7949, front side (top of illustration) and reverse side (bottom).
Preparations to Grind the Crankshaft
Inspection
Note: Special Instruction SEHS7949, Crankshaft Inspection Form , can be used each time a crankshaft is
inspected and/or ground. The single page form (front and reverse sides shown in Illustration 1) comes in pads of 50.
To check for journals that are not exactly round, Caterpillar recommends journal measurements 1, 2, and 3 (shown on
the form) be taken on each reground journal.
As a first step, inspect the crankshaft carefully. Look for any clear signs of damage that cannot be corrected by
reconditioning i.e. if a bearing or a bearing journal is heavily damaged, a journal is discolored (changed in color) or
shows signs of a spun bearing (the rotation of a bearing inside its bore). Refer to Guidelines for Reusable Parts and
Salvage Operations, SEBF8043 Visual Inspection of Crankshafts and SEBF8156 Procedure to Inspect
Crankshafts in 3500 Family of Engines for examples.
Also, check the hardness of the journal. Hardness specifications are given in SEBF8041. A low cost method to test
journal hardness is with a 6V-6035 Hardness Tester. If there is a soft area on any part of a journal, check the hardness
on either side of the soft area. The soft area is sometimes limited to just a small area at the journal surface. A hardness
test after the journal is ground can give a higher indication (reading). Other times, the soft area will go deep into the
journal. For these reasons, first grind the soft journal lightly, as a test. If the hardness indication is below 30 on the
Rockwell C (Rc) scale, there will be little or no improvement in the degree of hardness after the journal is completely
ground. Also, if there is aluminum bearing material on the journal, a low hardness indication is not necessarily correct.
Note: Grind damaged journals first. If they cannot be ground to the acceptable undersize dimension and hardness, the
crankshaft cannot be used again.
Check the crankshaft, using the procedures in Guideline for Reusable Parts and Salvage Operations, SEBF8054,
Procedures to Measure and Straighten Bent Crankshafts , and the specifications in SEBF8041, to see if it needs to
be straightened. If the crankshaft must be straightened, follow the instructions given in SEBF8054.
NOTICE
Never use a hammer, chisel, or any similar tool in

the fillet radii during any procedure to straighten,
as this will damage the crankshaft.
While it is easier to get good results if the crankshaft is straightened first, a small amount of bend (curve) can be
removed, as the crankshaft is ground. But remember the amount of bend that can be removed by this method has a
direct relation to the amount the main journals are ground undersize. For example, if the main journals are ground
undersize, the maximum amount of full length bend that can be removed is limited to just under 0.12 mm (0.005 inch).
If the main journals are ground 0.50 mm (0.020 inch) undersize, just under 0.25 mm (0.010 inch) of bend can be
removed.
Equipment
Preparations for use of the grinding machine must be made according to the machine manufacturer s
recommendations. There are many grinding machines available, and each model has specific controls and procedures
that must be followed in order to get acceptable results. Illustration 2 shows a typical grinding machine.
Correct selection of the size of the grinding machine is also important. Be sure the grinding machine has the necessary
capacity for the crankshaft being ground. In order to grind the longest Caterpillar crankshaft, (with exception of the
3600 Family of Engines) used in the D399 Engine, the grinding machine must have a minimum measurement of 2591
mm (102 inch) between its centers.
Illustration 2
Typical crankshaft grinding machine.
Chart A lists approximate lengths of the larger Caterpillar crankshafts.
Chart A.
Crankshaft Lengths
Model Dimension
D346 D343, 5.4 in Bore 90 1270 mm (50 inch)
V8, 3406, 3408, etc.
3412 1300 mm (51 inch)
D379 1450 mm (57 inch)
3508 1462 mm (58 inch)
D348 1500 mm (59 inch)
D353 1750 mm (69 inch)
D342 1880 mm (74 inch)
D349 1900 mm (75 inch)
3512 1972 mm (78 inch)
D398 2000 mm (79 inch)

3516 2510 mm (99 inch)
D399 2591 mm (102
inch)
3606 2921 mm (115
inch)
3608 3734 mm (147
inch)
3612 3226 mm (127
inch)
3616 4140 mm (163
inch)
Note: A grinding machine that is larger than necessary, will not operate efficiently.
Grinding machines should be equipped with these necessary items:
• Steady rest (refer to Illustration 3)
• Dressing attachment, plus diamond dressing tool (refer to Illustration 7)
• Journal truing attachment with dial indicator (refer to Illustration 9)
These items are normally sold separately:
• Continuous measurement attachment to be used while the crankshaft is ground (refer to Illustration 10).
• Polisher to be used with Scotch Brite belts (refer to Illustration 14)
• Equipment to check balance of grinding wheels
• Grinding wheels of different widths
Illustration 3
Typical steady rests.
Grinding Machine Manufacturers
Zanrosso
Via Galileo Galilei, 19-P.O. Box 70
36034 Malo
Vicenza, Italy
Telex: 843480192
Phone: (0445) 52 260
Grinders made by Zanrosso are available in the United States from:
Kwik-Way Manufacturing Company

500-57th Street
Marion, IA 52302 U.S.A.
Phone: (319) 377-9421
Kwik-Way also makes grinding machines of its own.
Rogers Machine Company

P.O. Box 318
Bay City, MI 48707 U.S.A.
Telex: 227497
Phone: (517) 892-5311 or 800-248-5062 from outside Michigan
Schou & Co. Ltd.

38 Krogshoejvej,
DK-2880 Bagsvaerd,
Denmark
Telex: 374 73 SCHOU DK
Phone: 2-9812 44
Grinders made by Schou are available in the United States from:
BERCO S.p.A.
44034 Copparo,
Ferrara, Italy
Telex: 51089 or 51384 BERCO
Phone: (0532) 860351
Grinders made by BERCO are available in the United States from:
Peterson Machine Tool, Inc.

5425 Antioch Drive
P.O. Box 278
Shawnee, KS 66202-1094 U.S.A.
Cable: PETMACTINC
Telex: TLX4-2532
Phone: (913) 432-7500
RUAROS S.p.A (SCLEDUM)

VIA PROE (ZONA)
36034 San Vito Di Leguzzano (VI)
P. O. Box 165 36015
Schio (VI), Italy
Telex: 481070 SLED 1
Phone: 0445/27444
Grinders made by SCLEDUM are available in the United States from:
Storm Vulcan, Inc.

2225 Burbank Street
Dallas, TX 75235 U.S.A.
Phone: (214) 637-1430
Grinding Machine Accessories
Grinding Wheels
Norton Company
1 New Bond Street
Worcester, MA 01601 U.S.A.
Phone: (508) 795-5000
Cincinnati Milacron
4701 Marburg Avenue
Cincinnati, OH 45209 U.S.A.
Phone: (513) 841-6200
Carborundum Company
5240 St. Charles Road
Melrose Park, IL 60160 U.S.A.
Phone: (312) 547-3700
Coolant
Chem Tool
8200 Ridgefield Road
P.O. Box 496
Crystal Lake, IL 60014 U.S.A.
Phone: (815) 459-1250
Cincinnati Milacron
4701 Marburg Avenue
Cincinnati, OH 45209 U.S.A.
Phone: (513) 841-6200
Wynn s Oil Company

2600 E. Nutwood Avenue
P. O. Box 4370
Fullerton, CA 92631 U.S.A.

Phone: (714) 992-2000
Grinding Wheels
Selection and Application
Check with the grinding wheel manufacturer to be sure that the wheel is of the correct size, grade, and grit for the job.
Caterpillar recommends using an aluminum oxide grinding wheel since Caterpillar crankshafts are made from a
hardened steel forging.
The width of the crankshaft journal is an important basis for selection of the grinding wheel. The grinding wheel
widths for Caterpillar crankshafts are given by model number in SEBF8041. This publication also gives fillet radii
dimensions.
The best grinding method is to use a correctly dressed wheel with a capacity to grind a complete journal at one time.
Use of a wheel that is a little wider than the bearing width, so that it can grind the complete bearing surface at one time,
will give more regular and flat journal profiles. It will also increase the service life of bearings (refer to the section
titled Procedure to Check Profile in SEBF8054). Dress the wheel to the correct width given in chart D in
SEBF8041. Refer to the section Procedure to Grind in this Guideline, if a narrow grinding wheel must be used.
Procedure to Inspect the Grinding Wheel
A cracked wheel can disintegrate and cause

personal injury.
It is also important to inspect the grinding wheel for cracks and damage, especially on the edges. To inspect for cracks,
hang the wheel from a hook so it can be visually inspected from all sides. Tap the wheel lightly with a nonmetallic
object (the handle of a screwdriver or hammer) six inches from the outside of the wheel at eight to ten places. A wheel
with a crack will sound like a dull thud instead of the normal ringing sound. Never use a wheel, which has a crack, no
matter how small.
The grinding wheel supplier can provide more information on correct wheel mounting and tightening procedures.
Procedure to Check Grinding Wheel Balance
It is very important for the wheel to be balanced before it is installed on the grinding machine.
An out-of-balance or cracked wheel can

disintegrate and cause personal injury. An out-of-
balance wheel will also cause out-of-round
journals.
Check the wheel and, if necessary, correct the balance according to the manufacturer s recommendations (refer to
Illustration 4).
Illustration 4
Install and check the wheel for cracks and for correct balance, according to the manufacturer s instructions.
Procedure to Dress the Grinding Wheel
Keep the wheel dressed so the face that grinds the bearing journal is flat and the fillet radii blend (give a smoothly
ground surface) between the journal and the sidewall (refer to Illustration 5). The bottom half of the fillet radii must
not have any steps or grooves that could possibly cause the crankshaft to break (refer to Illustration 6).
A very small dip is permissible at the junction of the fillet and bearing journal surface. Sometimes, this area can be a
little rough from grinder wheel breakdown (when small particles of the grinding wheel break off as the wheel is pushed
into the fillet). This rough area is acceptable in the bottom 20 percent of the fillet only if there are no rough edges
present.
Illustration 5
Action of the radius dressing tool.
Illustration 6
The fillet surface between the sidewall and journal surface must be ground smoothly to give an even surface.
The fillet radii on the grinding wheel must also blend smoothly with the wheel s sides and face. The correct
dimensions for fillet radii are given in SEBF8041.
A sharp diamond, correct speed of wheel rotation (rpm), and feed (rate of cut) are important factors during the
procedure to dress the wheel (refer to Illustration 7).
How the dressing tool is used has a direct effect on the final surface of the crankshaft journal. A heavy cut will give a
coarse surface finish; a light cut will give a fine surface finish. A cut of 0.02 mm (0.001 inch) on the last pass of the
dressing tool will help eliminate grinder burns on the side and face dress.
Illustration 7
Dressing the wheel face.
The speed with which the dressing tool is moved across the wheel will also have an effect on the surface finish. For
example, grinder burn can result if the dressing tool is moved too slowly across the surface of the wheel. A feed rate of
762 mm (30 inch) per minute is a good starting point.
At all times, use coolant during the complete procedure to grind and dress. Diamond dressing tools expand rapidly
when coolant is not used. A taper in the side or face dress will result.
Note: Watch for grinder burns on the surface. A grinder burn can cause the sidewall or journal to become very hot
which can cause very small cracks. Any time there is a grinder burn, inspect with magnetic particle inspection
equipment.
Miscellaneous
The sides of the grinding wheel must be kept dressed to prevent any contact between the sides of the wheel and the
counterweights on the crankshaft (refer to Illustration 8). Contact is possible if the counterweights have any distortion.
If contact occurs, removal of a very small amount of material from the counterweight is permissible. If more than just
a very small amount of material (approximately 3 grams or 0.1 ounces for crankshafts for 3208 Engines; a little more
for others) is removed from the webs or counterweights, the balance of the crankshaft must be checked and corrected
(if necessary).
Illustration 8
Dressing the wheel side.
Note: Heavy contact with the counterweight can also be caused by a soft (bent) journal.
Chatter or vibration of the crankshaft can occur if the grinding wheel rpm, crankshaft rpm, and feed have not been
correctly selected. An incorrectly balanced wheel can also cause chatter and vibration. The selection of the correct
rpm and feed as well as the correct balance for each crankshaft are especially important because crankshafts of similar
length and stroke can have different characteristics of resistance to vibration.
The direction of crankshaft rotation for the last grind must be opposite to that during engine operation. (Remember that
during the polish procedure the direction of crankshaft rotation must be the same as during engine operation.)
The final grind must be held to a maximum of 0.50 micrometers (20 microinches) so the crankshaft can be polished to
0.25 micrometers (10 microinches) maximum.
The type and quantity of coolant used during the grinding procedure is also important. The wrong solution can
decrease the wheel s ability to cut, as well as its capacity as a heat conductor. Use enough coolant to prevent a
concentration of heat in one area. The coolant must also be kept clean. A dirty solution can have an adverse effect on
the quality of the finished product. Follow the grinding machine manufacturer s recommendations for the correct
solution and mixture.
Procedure to Grind the Crankshaft
Personnel
Thorough training of service personnel in crankshaft grinding procedures is important. The majority of crankshaft and
bearing failures on ground crankshafts are the result of either defects in workmanship (quality of work) or a failure to
inspect the crankshaft for defects in workmanship. Diesel engine crankshafts must be ground very carefully. A high
level of precision and accuracy is needed on the part of service personnel in order to grind to exact specifications.
Procedure to Grind
NOTICE
During grinding procedure, prevent any

operations, which can change the stroke length of
the rod journals. Incorrect stroke lengths can have
an adverse effect on combustion pressures or
cause pistons to come in contact with parts of the
cylinder head, resulting in engine damage. Since
the procedure to grind a bent crankshaft can
possibly have an adverse effect on stroke length,
Caterpillar recommends the crankshaft be
straightened (by the application of heat and then
by the use of a press) before it is ground.
During the procedure to grind, the steady rest is used as a support to prevent crankshaft vibration (movement from the
centerline of rotation). Use of the steady rest is important because heavy pressure on the crankshaft, mainly caused by
incorrect feed, but also caused by a wider than necessary or incorrectly dressed wheel, can push the crankshaft away
from the wheel. To get the correct surface finish, the operator must learn to keep the rate of feed and resistance on the
steady rest carefully balanced. Follow the grinding machine manufacturer s recommendations.
To grind the main journals, put the crankshaft in the chucks. Check each journal s position with an indicator to be
sure its rotation is exactly on center. When grinding the main journals on a crankshaft from a 3600 Engine, the depth
clearance for the counterweight and the grinding wheel is 210.00 mm (8.25 inch) minimum.
To grind the connecting rod journals, adjust the stroke according to SEBF8041. When grinding the rod journals on a
crankshaft from a 3600 Engine, the depth clearance for the counterweight and the grinding wheel is 381.00 mm (15.00
inch) minimum. Follow the grinding machine manufacturer s recommendations for all other details. Illustration 9
shows how to use a dial indicator to be sure the rod journal is exactly on center.
Illustration 9
Rotation of the rod journals must be exactly on center.
It is not usually necessary to use the steady rest until the complete surface has cleaned up . But since some
crankshafts are more flexible than others and because of differences in wheel pressures, it is possible that the steady
rest will have to be used when the surface is only 50 to 75 percent cleaned up .
To prevent an out-of-round condition caused by heavy wheel or steady rest pressure, use a dial indicator in direct
contact with the surface being ground (refer to Illustration 10). By using the dial indicator in direct contact with the
surface, there is not only a constant check for out-of-round, but also an immediate indication when the journal is
ground to the desired size.
Illustration 10
The dial indicator checks the surface being ground.
It may be necessary to use a wheel that is narrower than the width shown in SEBF8041 because there are so many
different journal widths. A narrower wheel will not grind the journal in a single movement, and it will be more
difficult to get a smooth and even journal profile. It is important to chose the correct speed and exact wheel location.
1. Move the wheel in until it makes contact with the journal surface and then to the left until it starts to grind the left
fillet radius.
2. Move the wheel in and grind until the journal diameter is 0.05 to 0.08 mm (0.002 to 0.003 inch) from the desired
undersize dimension.
3. Move the wheel out and toward the right fillet radius. As soon as the fillet surface starts to grind, slowly move the
wheel in and grind to the desired undersize dimension. Let the cutting action of the wheel stop or spark out before
moving it to the left.
4. Slowly move the wheel to the left, and remove any extra material from the surface. Let the wheel spark out
again while moving it to the left.
5. Carefully move the wheel all the way to the left until it starts to grind the fillet radius. Grind to the exact size.
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 ground independently. This allows for the use of narrower grinding wheels, which are more
commonly available. See Chart D of SEBF8041 for acceptable grinding wheel dimensions. This process may result in a
ground step in the center of the rod journal. This step must be entirely located in the area shown in Illustration 11.
The dimensions of the step cannot exceed a maximum height of 0.0177 mm (0.0007 inch) or a maximum width of 0.89
mm (0.035 inch) shown in Illustration 12.
Other than this ground step feature, all normal finish requirements found in Chart C of SEBF8041 apply. In the 2 mm
(0.08 inch) wide zone, no surface irregularities other than the ground step are allowed.
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 11
3412 Rod Journal Ground Step Location

(1) Any surface discontinuity due to double plunge grinding process is to be in this zone
(2) Zone Width 2 mm (0.08 inch)
(3) 41.3 mm (1.63 inch) Distance
(4) Surface Finish (SEBF8041 Chart C)
(5) Diameter (SEBF8041 Chart C)
Illustration 12
3412 Rod Journal Ground Step Dimensions

(6) Height
(7) Width
Procedure to Shot Peen
Caterpillar crankshafts must be shot peened or cold worked (use of a hard roller) after they are re-ground or re-
straightened if they were shot peened or cold worked when originally manufactured. Refer to Rolled Fillet
Crankshafts for additional information on rolled fillets. SEBF8041 indicates which crankshaft and the fillet(s) that
require shot peening.
Shot peening is a procedure by which an impeller wheel or air under pressure is used to send small round pieces of
metal (steel shot) against the fillets of a crankshaft at a high rate of speed. The impact of the shot increases the strength
of the metal surface and the service life of the crankshaft.
NOTICE
Make sure all bearing surfaces and any fillets or

sidewall areas that are NOT to be shot peened
have several layers of 5P-3046 Tape or some other
type of protection during the procedure. SHOT
PEEN MARKS ARE NOT PERMITTED ON
ANY JOURNAL SURFACE. Shot peen marks
cannot be removed by the procedure to polish.
The type of shot peening, as well as the degree of power used and the length of time taken, must be adjusted to get a
MINIMUM arc height of 0.28 mm (0.011 inch) on an SAE Almen test strip, type A . The Almen test strip will be
peened with the crankshaft removed from the shot peening machine. To measure the impact of the shot, it is important
that the test strip be peened at the same distance and angle as the fillet. Almen test strips and gauges are available from
manufacturers of shot peening and shot cleaning equipment.
After shot peening, all holes must be thoroughly cleaned to remove any particles of metal.
Rolled Fillet Crankshafts
Grinding the journals of crankshafts having rolled fillets requires special processing and the use of special fillet rolling
equipment. Grinding the journals without reworking the fillets would remove strength from the crankshaft. If fillet-
rolling equipment is not available, the journals and fillets can be ground as long as the fillets are shot peened after
grinding.
Process fillets as follows as shown in Chart B.
Chart B.
Type of Fillet and Processing Requirements
Type of Fillet Illustration No. Fillet Processing
Ground 13 Grind
Rolled 14 Grind & roll or
grind & shot
peen
Shot peened 15 Grind & shot
peen
In general, the fillet radii on rolled fillet crankshafts are smaller than the radii on similar, ground fillet crankshafts. The
radii on rolled fillet crankshafts can be ground to the larger radii of similar crankshafts as long as the fillets are shot
peened following grinding.
Illustration 13
Ground fillet. Note the shiny finish of the journal OD and the smooth transition from the journal OD to the fillet.
Illustration 14
Rolled fillet. Rolled fillets have a smaller radii compared to the ground fillet.
Illustration 15
Shot peened fillet. These fillets have a dull gray appearance compared to the shiny finish of the journal OD.
Procedure to Polish
Use the following equipment and procedure to polish (make smooth) crankshaft journals to a 0.15 to 0.20 micrometer
(6 to 8 microinch) surface finish with minimum change to the crankshaft profile.
Note: Do not remove any metal during the procedure to polish.
Surface finish has a direct effect on bearing wear, so the bearing journal must be correctly polished to a surface finish
of 0.25 micrometer (10 microinch) or smoother. During the procedure to polish, the crankshaft journal profile must be
kept to acceptable tolerances. (It is possible that journal profile can change if more than 0.010 mm (0.0004 inch) of
material is removed from the journal diameter.) Refer to SEBF8054 for instructions on profile measurement.
Use either a polisher attachment on the grinding machine or a portable polisher (refer to Illustration 16). Remove any
metal particles and/or sharp edges in and around the oil holes. The oil holes must then be polished by hand. Refer to
SEBF8042, Procedure to Polish Crankshafts , for details of correct equipment and procedures.
Equipment Needed to Polish Crankshaft Journals
High Speed Polisher
Use an electric or air-powered high-speed polisher. Refer to Illustration 16. The polisher must have the power to move
a 25 x 1650 mm (1.0 x 65.0 inch) belt at approximately 1220 surface meters per minute (4000 surface feet per minute).
Illustration 16
Electric high speed polisher with polishing belt in position.
For information on high speed polishers and details on import procedures, contact:
Kwik-Way Manufacturing Co.

500-57th Street
Marion, IA 52302 USA
Phone: (319) 377-9421
Peterson Machine Tool, Inc.

5425 Antioch Drive
P.O. Box 278
Shawnee Mission, KS 66204 USA
Cable: PETMACTINC
Telex: TLX4-2532
Phone: (913) 432-7500
Storm Vulcan
2225 Burbank Street
Dallas, TX 75235 USA
Phone: (214) 637-1430
Polishing Belt
Use a 6V-3044 Polishing Belt with the high-speed polisher. The

NOTICE 6V-3044 Polishing Belt is a 3M Company, Scotch-Brite Blend 'N
Finish, Type S Super Fine Belt. When used correctly, it will give
Caterpillar Inc. recommends using Scotch a constant 0.15 to 0.20 micrometer (6 to 8 microinch) surface
Brite belts instead of emery polishing paper. finish with a minimum amount of change to the crankshaft
Emery polishing paper can change the profile of profile. The 6V-3044 Polishing Belt is self-lubricating. At all
the journal. times, install the belt so rotation will be in the direction of the
arrow on the belt.
If the correct Scotch-Brite belt is used, no lubricant is necessary to get a surface finish of 0.15 to 0.20 micrometer (6 to
8 microinch). For a smoother finish [approximately 0.125 micrometer (5 microinch)] necessary for the 3500 Family of
Engines, Caterpillar has found one special lubricant, ACCU-LUBE that works well with the Scotch-Brite belt.
ACCU-LUBE cutting lubricant is available from:
M-R-S Industrial
512 SW Washington St.
Peoria, IL 61602 USA
Telephone: (309) 673-5118
(800) 322-2662
Accu-Lube is available in a solid and a liquid. It is a Caterpillar recommendation to use the liquid with a spray squeeze
bottle or atomizer bottle. Use as little of the lubricant as possible; put only a light "mist" on the journal.
Chart C.
Accu-Lube
M-R-S Part No. Description
530-45800521 LB-2000 Liquid 3.8 L (1 gal)
530-45800523 LB-2000 Liquid 208 L (55 gals)
530-45800754 Solid (tube) 368 g (13 oz)
Surface Finish Analyzers
It is critical to maintain surface finish after polishing. A poor surface finish will result in reduced bearing life. Refer to
the following list of suppliers for surface analyzers.
Illustration 17
Surface finish analyzer in use.
Rank Taylor⎯Hobson
P.O. Box 36 Guthlaxton Street

Leicester LE2 OSP
England
Telephone: 011-44-116-276-3771
Telex: 851-3441
Cables: Metrology Lestr
Bendix, Automation and Measurement Division
7221 Springfield Street

P.O. Box 1127
Dayton, OH 45401 U.S.A.
Telephone: (513) 254-5377
Telex: 288031
Societe Commerciale D'Expansion S.A.
6, place des Eaux-Vives

1207 Geneve, Switzerland
Telephone: 011-41-22-736-65-60
Cable: Ecoma Ch
Telex: 22642
Mitutoyo Manufacturing Co.
18 Essex Road
Paramus, NJ 07652 U.S.A.
Telephone: (201) 368-0525
Federal Products Corp.
1144 Eddy Street

Providence, RI 02901 U.S.A.
Telephone: (401) 781-9300
Telex: 927623 FED.GAGE PVD
Equipment for Rotation of Crankshaft
An engine lathe, crankshaft grinder, finishing or polishing lathe must be used to turn the crankshaft on centers while the
journals are polished. Rotation speed must be between 30 and 60 rpm.
Note: The distance between centers for the largest Caterpillar crankshaft is 2590.8 mm (102.00 inch). Refer to Chart A,
for more information on lengths of Caterpillar crankshafts.
Finishing machines and polishing lathes are available from:
Storm Vulcan
2225 Burbank Street
Phone: (214) 637-1430
Note: A 1650 mm (65.0 inch) polishing belt will NOT fit on the Storm Vulcan finishing machine. Order the correct
size belt from 3M Company; contact one of the branch offices listed in the next section of this Guideline for the address
of a local distributor.
Cartridge Roll and Mandrel
Generally, the oil hole does not need to be polished unless the crankshaft has been ground undersize. If the oil hole has
sharp edges, remove any burrs and polish.
Use a 25 mm (1.0 inch) long 220 grit "3M-lte Resinite Cloth" full taper cartridge roll with a 25 mm (1.0 inch) base
diameter. Install the cartridge roll on a 3M Company A-18D screw-type mandrel with a 3.18 mm (0.125 inch) pilot
diameter, 25 mm (1.0 inch) pilot length and 6.4 mm (0.25 inch) shank diameter. Refer to Illustration 18. Turn the
mandrel and cartridge roll with an electric or air-powered drill.
Illustration 18
Cartridge roll and mandrel.
To find local distributors in U.S., contact one of these 3M Company branches:
ATLANTA
2860 Bankers Industrial Dr.
Atlanta, GA 30360 USA
Phone: (404) 447-7000
CHICAGO
6850 South Harlem Avenue
Argo, IL 60501 USA
Phone: (312) 496-6500
CINCINNATI
4835 Para Drive
Cincinnati, OH 45237 USA
Phone: (513) 242-2313
CLEVELAND
12200 Brookpark Road
Cleveland, OH 44130 USA
Phone: (216) 362-1700
DALLAS
2121 Santa Anna Avenue
Mail to: P. O. Box 28158
Phone: (214) 324-8100
HONOLULU
4443 Malaai Street
Honolulu, HI 96818
Honolulu, HI 96820
Phone: (808) 422-2721
LOS ANGELES
6023 South Garfield Ave.
Los Angeles, CA 90040 USA
Phone: (213) 726-6300
NEW YORK
15 Henderson Dr.
West Caldwell, NJ 07006 USA
Phone: (201) 575-2000 (NJ)
(212) 285-9600 (NY)
ST. PAUL/MINNEAPOLIS
3130 Lexington Avenue, South
Eagan, MN 55121 USA
Mail to: P.O. Box 33211
St. Paul, MN 55133 USA
Phone: (612) 733-3300
To find local distributors outside the U.S., contact one of these 3M Company Export Sales Offices:
EXPORT SALES OFFICE

3M Company
512 Fifth Avenue, Room 1801
New York, NY 10017 USA
Cable: MIMACO
EUROPE AREA OFFICE

3M Europe S.A.
53/54 Avenue des Arts
1040 Brussels, Belgium
Cable: TRIMINCO-BRUSSELS
SOUTHEAST ASIA AREA OFFICE

3M Southeast Asia Pte. Ltd.
22nd Floor, Rooms 2201-2212
51 Goldhill Plaza
Singapore 11
Cable: TRIMSEA-SINGAPORE
EASTERN EUROPE SALES OFFICE

3M East A.G.
Baarestrasse 8
P.O. Box 6301
Zug. Switzerland
Cable: TRIMINCO-ZUG
Polishing Stick
Polish the thrust surfaces with a 50 x 6.4 x 762 mm (2.0 x 0.25 x 30.0 inch) polishing stick made of wood. Fasten 180
grit emery polishing paper to the 50 mm (2.0 inch) face.
Procedure to Polish Journals
1. Inspect the journal according to instructions given in SEBF8054 and dimensions given in SEBF8041. Be sure to
polish ONLY those journals that need to be polished.
2. Install the crankshaft on the polishing lathe or crankshaft grinder so that the crankshaft will turn in the same
direction as it would in the engine. (Normally, this direction is counterclockwise as seen from the flywheel end of the
crankshaft.)
3. If the oil holes have sharp edges, use the cartridge roll, mandrel and drill to remove burrs and polish the oil hole
radius. Polish the oil hole until all sharp edges are removed.
NOTICE
Be very careful not to let the cartridge roll come in

contact with the bearing journal surface.
Illustration 19
Direction of polishing belt in relation to rotation of crankshaft.
4. After all the oil holes are inspected and polished, polish the bearing journal surface with the weight of the high-
speed polisher on the 6V-3044 Polishing Belt. The direction of the polishing belt MUST be as shown in Illustration 19.
The belt does not need to be "broken-in" (special treatment) before use and can be used wet or dry.
On 3600 Engines, the first polishing operation should use a rotation opposite of the final grind operation. Crankshaft
rotation shall alternate with each succeeding polishing operation.
Polish the journal only during rotation of the crankshaft. During rotation, move the polishing belt slowly and evenly
across the journal surface into the fillets. Do not polish in the same place for more than 15 seconds.
Generally, the journal will be polished in 15 to 120 seconds, If, after this time, the journal surface finish is still more
than 0.25 micrometer (10 microinch), the original journal surface was too rough.
Note: The journal surface finish must be less than 0.63 micrometer (25 microinch) after it is ground. If the profile is
acceptable, polish the journal until the surface finish is acceptable. Check the profile of the journal carefully after the
procedure to polish.
5. Polish the thrust face with the polishing stick until all the bearing material and burrs are removed. Measure the
thrust face dimension according to SEBF8041.
After the crankshaft has been polished, remove the crankshaft oil plugs and clean the oil passages with solvent and
brushes. See SEBF8043 for more information.
Inspection and Measurement
After the crankshaft has been ground and polished, make a complete inspection, and check all dimensions. Make a
record of all measurements on the Crankshaft Inspection Form shown in Illustration 1.
Check the hardness of all the ground journals according to SEBF8041. Hardness indications (readings) that are slightly
below the permissible amount are acceptable only if the indications are approximately the same on all journals.
Specifically, below normal hardness indications are acceptable if the maximum difference between indications is no
more than 3 Rockwell C points on all journals.
For example, according to SEBF8041, if an acceptable Rockwell C minimum journal hardness is 48 and the indications
on the rod journals are 43, 47, 48, 47, 47, and 45, the crankshaft cannot be used again since there is a 5 point difference
between the highest and lowest indications.
Next, check the radii dimensions. This must be done before any shot peening operation. Then check for out-of-round,
taper, bend, profile, diameter, surface finish, and thrust face dimensions against specifications given in SEBF8041.
When all measurements are taken and checked against specifications, inspect for cracks with magnetic particle
equipment according to the instructions given in SEBF8039.
If, during the inspection and measurement procedure, any dimensions are not acceptable or cracks are still found after
the journal is ground again, grind to the next undersize dimension if possible.
Procedure to Clean the Crankshaft
A ground crankshaft must be thoroughly cleaned before shipment. Use an air hose to remove coolant, sludge, steel
shot, and metal particles from oil passages. Then use brushes from the 6V-3184 Brush Group to clean the oil passages
from both the rod and main journal ends and from the lightening hole or plug end. Flush the oil passages with solvent
to make sure they are completely clean. Use an inspection light and a magnet to check each hole.
Storage
Corrosion will start immediately after the crankshaft has been ground, polished, or cleaned. A layer of oil must be put
on the complete crankshaft, including inside the oil holes, for protection during storage. Refer to SEBF8043, Visual
Inspection of Crankshafts .
© 2004 Caterpillar
Printed in the U.S.A
All Rights Reserved
Copyright 1993 - 2006 Caterpillar Inc. Wed Jul 12 15:03:03 UTC+0700 2006
All Rights Reserved.
Private Network For SIS Licensees.

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3126 Industrial Engine CKK00001-UP(SEBP3371 - 12)/Basic Search Page 1 of 31

Product: INDUSTRIAL ENGINE

Reuse And Salvage Guidelines

Procedure to Grind and Polish Crankshafts

Equipment and Tooling

Equipment and Tooling1

Never use a hammer, chisel, or any similar tool in

Typical crankshaft grinding machine.

Chart A lists approximate lengths of the larger Caterpillar crankshafts.

D398 2000 mm (79 inch)

Grinding machines should be equipped with these necessary items:

• Steady rest (refer to Illustration 3)

• Dressing attachment, plus diamond dressing tool (refer to Illustration 7)

• Journal truing attachment with dial indicator (refer to Illustration 9)

These items are normally sold separately:

• Polisher to be used with Scotch Brite belts (refer to Illustration 14)

• Equipment to check balance of grinding wheels

• Grinding wheels of different widths

Typical steady rests.

Grinding Machine Manufacturers

Grinders made by Zanrosso are available in the United States from:

Kwik-Way Manufacturing Company

Kwik-Way also makes grinding machines of its own.

Rogers Machine Company

Phone: (517) 892-5311 or 800-248-5062 from outside Michigan

Schou & Co. Ltd.

Grinders made by Schou are available in the United States from:

Grinders made by BERCO are available in the United States from:

Peterson Machine Tool, Inc.

RUAROS S.p.A (SCLEDUM)

Grinders made by SCLEDUM are available in the United States from:

Storm Vulcan, Inc.

Grinding Machine Accessories

Wynn s Oil Company

Fullerton, CA 92631 U.S.A.

Selection and Application

Procedure to Inspect the Grinding Wheel

A cracked wheel can disintegrate and cause

Procedure to Check Grinding Wheel Balance

An out-of-balance or cracked wheel can

Procedure to Dress the Grinding Wheel

Action of the radius dressing tool.

Dressing the wheel face.

Dressing the wheel side.

Procedure to Grind the Crankshaft

During grinding procedure, prevent any

Rotation of the rod journals must be exactly on center.

The dial indicator checks the surface being ground.

3412 Rod Journal Ground Step Location

3412 Rod Journal Ground Step Dimensions

Make sure all bearing surfaces and any fillets or

Rolled Fillet Crankshafts

Process fillets as follows as shown in Chart B.

Note: Do not remove any metal during the procedure to polish.

Equipment Needed to Polish Crankshaft Journals

High Speed Polisher

Electric high speed polisher with polishing belt in position.

Kwik-Way Manufacturing Co.

Peterson Machine Tool, Inc.

Use a 6V-3044 Polishing Belt with the high-speed polisher. The

ACCU-LUBE cutting lubricant is available from:

Surface Finish Analyzers

Surface finish analyzer in use.

P.O. Box 36 Guthlaxton Street