SEBF8054 - Procedure To Measure and Straighten Bent Crankshafts

3126 Industrial Engine CKK00001-UP(SEBP3371 - 12)/Basic Search Page 1 of 28
Shutdown SIS
Previous Screen
Product: INDUSTRIAL ENGINE

Model: 3126 INDUSTRIAL ENGINE CKK
Configuration: 3126 Industrial Engine CKK00001-UP
Reuse And Salvage Guidelines

Procedure to Measure and Straighten Bent Crankshafts
Media Number -SEBF8054-08 Publication Date -31/08/2004 Date Updated -31/08/2004
SEBF80540001

SMCS - 1202
CATERPILLAR®
GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS
Summary of Revisions
Page Description
All Revised the format.
All This guideline has been revised with

new information.
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.
https://tu-tc-nt2:8443/sisweb/servlet/cat.dcs.sis.controller.techdoc.CSSISFormatTechDocForPrintServlet?... 7/12/2006
For questions or additional information concerning this guideline, contact Caterpillar Service Support Division, Dealer
Support (309) 494-1934.
Summary
A used crankshaft must be checked for taper, out-of-round, thrust face wear, profile, and surface finish. If the
crankshaft is ground undersize, the radius and journal hardness must also be checked. All crankshafts that are used or
ground undersize must also be checked for straightness.
This guideline provides information on the procedures and the tools required to measure a used/reground crankshaft to
see if it can be used again. If a crankshaft meets the specifications found in this guideline, it can be expected to give
normal performance until the next overhaul when used again in the same application.
Measurement information in this guideline is given in five areas:
• Procedure to determine if a crankshaft can be used again as is (Procedure to measure used crankshafts for
bend)
• Procedure to measure crankshafts after the bearing journals are ground
• Procedure to determine if a bent crankshaft can be straightened
• Straightening a bent crankshaft
• Crankshaft measurements
Some bent crankshafts can be used again if they are straightened. Measuring the crankshaft carefully is the first step in
the salvage procedure.
Refer to SEBF8041, Crankshaft Specifications for the Use Again measurements required in order to determine
the reusability of most used crankshafts.
References
Reference Material
Form No. Title
SEBF8039 Inspection of Crankshafts for
Cracks
SEBF8041 Crankshaft Specifications
SEBF8042 Procedure to Grind and Polish
Crankshafts
SEBF8043 Visual Inspection of Crankshafts
SEBF8156 Procedure to Inspect Crankshafts
in 3500 Family of Engines
Tooling and Equipment
Tooling and Equipment1

Part Number Part Description
7H-1940 Universal Attachment2
7H-1942 Dial Indicator2

7H-1944 Post2
7H-1948 Snug2
8S-2329 Dial Indicator Base2
5P-4163 Contact Point3
5P-8637 Support Groups (V-Blocks)
6V-6035 Hardness Tester
7B-0337 Surface Plate
- Radius Gauges
1 Refer to the latest version of NENG2500 Tools and Shop Products Guide , for any changes.
2 This tooling is part of the 8T-5096 Dial Indicator Test Group.
3 This tooling is part of the 6V-7926 Dial Indicator Group.
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
Before spending valuable time performing a magnetic particle inspection, measuring, straightening and grinding a
potentially scrap crankshaft, perform the following visual checks first to ensure the part is a good candidate for reuse.
Note: When inspecting crankshafts, refer to SEBF8039 Inspection of Crankshafts for Cracks and SEBF8043
Visual Inspection of Crankshafts for additional information.
If the crankshaft was removed from a running, assembled engine
1. Examine all surfaces of the crankshaft for discoloration caused by excessive heat. Do not reuse any parts removed
from an engine that have been involved in a vehicle fire.
2. Examine the exterior surfaces of the crankshaft for physical damage - nicks dents, large cracks, etc.
3. Examine the connecting rod and main bearing journals for deep scratches, cracks in the fillets, metal transfer due to
lack of lubrication, evidence of damage due to improper grounding during welding.
Note: Any of the above features will disqualify a crankshaft from being reused.
If the crankshaft was received as a disassembled core
1. Examine all surfaces of the crankshaft for discoloration. Any crankshaft that has gotten excessively hot should not
be reused.
2. Examine the complete crankshaft for signs of rust and corrosion.
Note: Any of the above features will disqualify a crankshaft from being reused.
3. Make certain the crankshaft is correct for the intended engine application.
4. If the crankshaft is to go into a Caterpillar engine, make certain the crankshaft is also genuine Caterpillar.
One common job shop method used to straighten bent crankshafts is to grind the bearing surfaces to a smaller
diameter. This method is limited, because the bearing surfaces must clean up (the complete surface must be ground)
and the finished size must not be smaller than the next available bearing undersize. In addition, it is much easier to
grind after the crankshaft has been straightened. Caterpillar recommends straightening all crankshafts (if necessary)
before grinding.
Note: Some marine societies and insurance companies do not approve the use of reground crankshafts in marine
engines. Contact the insurance company or marine society representative to determine whether reground crankshafts
are acceptable.
Procedure to Determine If a Crankshaft Can Be Used Again As Is

(Procedure to Measure Used Crankshafts for Bend)
Tooling Set-up
Illustration 1
Dial indicator with contact point
1. Use the dial indicator, base, post, snug, and rod from the 8T-5096 Dial Indicator Group with 5P-4163 Contact Point
from 5P-4165 or 6V-7926 Dial Indicator Group (Illustration 1).
Illustration 2
Support the crankshaft with V-blocks under the end main journals
2. Put two 5P-8637 Crankshaft Support Groups (V-blocks) on a surface plate or a concrete floor. Do not use a
workbench since the weight of the crankshaft can bend the workbench and cause an error in measurements.
Note: The V blocks should be aligned before and after placing the crankshaft on them. The aligning purpose is to
have both the V block bases an equal distance to an established reference point. (E.g., a secured metal strip that is
parallel to the edge of a surface plate or a "blue line" reference point on concrete.)
3. Support the crankshaft with V-blocks under the end main journals (Position 1, Illustration 2). Check the V-blocks
and crankshaft to ensure they are stationary and aligned. The crankshaft must rotate in the V-blocks, but must not
move horizontally.
Note: Ensure that the oil hole area does not come in contact with the center of the V-block and, if possible, keep the
V-block to one side of the crankshaft journal (but not into the fillet) so the crankshaft journal diameter is the only point
of contact with the V-block.
Illustration 3
Piece of steel with three pads to hold the dial indicator s magnetic base stationary
4. Use a piece of steel to hold the magnetic base for the indicator. Weld 3 pads, or spaces, 120 degrees apart under
the piece of steel to keep it stationary (Illustration 3).
Note: Use the same reference point in Step 2 to align the base of the indicator, this will ensure a more efficient set-up
and inspection procedure.
Illustration 4
5. Put the magnetic base for 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 V-block as shown in Illustration 4. The contact point must be to the side of
the oil hole, perpendicular (at a 90-degree angle) to the bearing surface and horizontal.
6. Once the adjustments are made, rotate the crankshaft 360 degrees to insure indicator travel is sufficient and adjust
indicator to zero.
Procedure for performing the measurement
Note: The Tooling Set-up Procedure must be performed each time the V-blocks are moved.
Illustration 5
Note: Assume that the tooling was set up on the main journal bearing (A)
1. With the crankshaft and tooling set-up as described above. Rotate the crankshaft 360 degrees and record the (TIR)
Total dial Indicator Reading. The TIR is the difference between the highest and lowest readings on the dial indicator
while the crankshaft is rotated.
Note: You can get a wrong TIR if the oil hole area comes in contact with the center of the V-block. If possible, keep
the V-block to one side of the crankshaft journal (but not into the fillet) so the crankshaft journal diameter is the only
point of contact with the V-block.
2. Move the dial indicator to the other main bearing journal (B) next to a V-block. Rotate the crankshaft as was done
in Step 1 and again record the TIR.
Illustration 6
3. Move each V-block 1 main bearing journal toward the center of the crankshaft as shown in Illustration 6 (Position
2).
Illustration 7
4. Measure the next main bearing journals located to the inside of and next to the V-block supports (C), as shown in
Illustration 7.
Illustration 8
Measurement of center main bearing
5. Continue the procedure until the center main bearing journal is measured as shown in Illustration 8.
Note: If there are two maximum points during measurement of TIR, use an outside micrometer and check for an out-
of-round main journal or an incorrect TIR caused when an oil hole area came in contact with a V-block.
Illustration 9
Crankshaft
(1) Pilot hub for flywheel (5) Flange for pulley, gear or damper
(2) Flange face for flywheel (6) Straight or tapered shaft
(3) Flange for flywheel (7) Flange face for pulley or damper
(4) Main bearing journals (8) Pilot hub for damper
Procedures to Measure Crankshafts after the Bearing Journals are Ground
If a crankshaft is reground, journals must be in alignment with other surfaces of the crankshaft. If the TIR for any of the
measurements that follow is more than specifications shown in SEBF8041, Crankshaft Specifications , the
crankshaft cannot be used again as is . If possible, grind the crankshaft to the next standard size and measure again.
Note: The bold numbers following the headings refer to Illustration 9 (crankshaft drawing).
Measurement of TIR on Hub Circumference (1) or Flange (3) for Flywheel
Illustration 10
Measurement of flange circumference for flywheel
1. Put V-Blocks under the front and rear main bearing journals. Put contact point for the dial indicator on the flywheel
pilot circumference as shown in Illustration 10.
Note: The contact point must not be in the wear groove of the rear crankshaft seal.
Illustration 11
Measurement of hub circumference for flywheel
2. The contact point must be perpendicular to the surface and at the approximate centerline of crankshaft. For all
engines with a pilot hub for the flywheel, put contact point for the dial indicator on the hub of crankshaft as shown in
Illustration 11.
Note: The pilot hub on a crankshaft can be much shorter than the pilot hub shown in Illustration 11. Refer to the notes
at the end of Chart A, Measurements of Reground Crankshafts.
3. Turn the crankshaft 360 degrees and check the TIR.
Measurement of TIR on Flange Faces for Pulley or Damper, and Flywheel (2 & 7)
Illustration 12
Measurement of flange face for pulley or damper on a lathe. This measurement can also be made with V-Blocks, a
hardened steel ball, and a heavy steel object.
Refer to How to Prevent Axial Movement of Crankshaft . Remove the 5P-4163 Contact Point. Install 7H-1940
Universal Attachment to dial indicator. Put the point for the universal attachment on face of flange for pulley or damper
as shown in Illustration 12. The point of the universal attachment must be near the outer circumference of flange face
so it will not hit the holes in the crankshaft. Turn crankshaft 360 degrees and check TIR. Use the same procedure for
the face of the flywheel flange.
Measurement of TIR on Main Bearing Journals (4)
Measure the main bearing journals as shown in Procedure to Measure Used Crankshafts for Bend . The maximum
TIR specification for the main bearing journals is 0.13 mm (0.005 inch) for any reground crankshaft.
Measurement of TIR on Front Flange (5), Straight Front Shaft (6) or Hub Circumference (8)
Perform the Steps outlined under Measurement of TIR on Hub Circumference (1) or Flange (3) for Flywheel 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 the TIR. Do not let the contact point hit a keyway.
Measurement of TIR on Tapered Front Shaft (6)
Illustration 13
Measurement of tapered surface
Refer to section How to Prevent Axial Movement of Crankshaft . Put contact point for the dial indicator near end of
tapered surface (refer to Illustration 13). The contact point must be perpendicular to tapered surface and at the
approximate centerline of the crankshaft. Turn crankshaft 360 degrees to check TIR. Do not let the contact point hit a
keyway.
How to Prevent Axial Movement of Crankshaft
The remainder of the measurements can be done with accuracy only if any axial movement of the crankshaft is
prevented. One method is to install the small and medium size crankshafts on a lathe in crankshaft machine centers
(machined holes in each end of crankshaft).
Note: Do not use a lathe to check TIR of main bearing journals of a large crankshaft. The weight of the crankshaft can
cause incorrect TIR measurements.
Illustration 14
Crankshaft with steel ball pushed against heavy steel object
A second method is to use V-Blocks with a 19.7 to 22.4 mm (0.62 to 0.88 inch) diameter steel ball that has been
hardened. Put the steel ball in the machined center on front end of crankshaft and push crankshaft and steel ball against
a heavy steel object as shown in Illustration 14. The heavy steel object must not move or be dented (pushed in) when
the crankshaft is pushed against it. The crankshaft must be held against the steel object while measurements are made.
Put oil on the steel ball.
Procedure to Determine if a Bent Crankshaft Can Be Straightened
Follow this procedure to measure overall TIR at the center main bearing.
Illustration 15
Crankshaft installed on V-Blocks. Measure TIR at center main journal only, to determine if crankshaft can be
straightened with safety.
1. Perform Steps 1 through 4 of Tooling Set-up under the Procedure to Determine If a Crankshaft Can Be Used
Again As Is
(Procedure to Measure Used Crankshafts for Bend) .
2. Place the contact point for the dial indicator on the center main bearing (C). Refer to Illustration 15. The contact
point must be to the side of the oil hole, perpendicular (at a 90 degree angle) to bearing surface and at the approximate
centerline of the crankshaft.
3. Once the adjustments are made, rotate the crankshaft 360 degrees to insure indicator travel is sufficient and adjust
indicator to zero.
4. Turn the crankshaft 360 degrees and check dial indicator. Make a note of TIR.
5. If TIR is within the specifications found in SEBF8041, Crankshaft Specifications , the crankshaft can be
straightened.
Straightening a Bent Crankshaft
Equipment Needed to Straighten Bent Crankshafts
Heating Oven
It is very important that an oven be used to heat the crankshaft. The oven must heat the crankshaft to 177 to 232°C
(350 to 450°F). To prevent cracks, do not straighten crankshaft at normal room temperature. Crankshaft temperature
can be measured with a thermometer or with 9U-7043 Temperature Recorder Crayons, which become liquid at specific
temperatures.
Hydraulic Straightening Press
A hydraulic straightening press is necessary to straighten the crankshaft. The press must be equipped with one or more
dial indicators to measure TIR on main bearing journals while the crankshaft is in the press.
Straightening presses are available from:
Dake Corporation
724 Robbins Road
Grand Haven, MI 49417 U.S.A.
Telephone: (616) 842-7110
telex: 228-459
Peterson Machine Tool, Inc.

5425 Antioch Drive
Shawnee Mission, KS 66201 U.S.A.
Telephone: (913) 432-7500
U.S.A. Cable Address: Petmactinc
TLX4-2532
Storm Vulcan, Inc.

2225 Burbank St.
Dallas, TX 75235 U.S.A.
Telephone: (214) 637-1430
The surfaces of the anvils and press ram that are in

contact with the crankshaft bearing surfaces must
be made of soft steel or copper to prevent damage
to bearing surfaces. Do not use brass or any
materials not made of metal because they can
shatter (break into many pieces) under high
pressure. Do not use 5P-8637 V-Blocks as
supports during the procedure to straighten
crankshaft.
NOTICE
Do not use anvils or press rams that are wider than

the bearing journal straight length (the length
between the radii at each end of the bearing
journal surface). Wider anvils or rams can cause
damage to the fillet area.
Magnetic Crack Detection Equipment
A crankshaft that has been straightened must be checked for cracks. Use magnetic crack detection equipment after the
straightening procedure is completed.
Refer to Guideline for Reusable Parts, SEBF8039, Inspection of Crankshafts for Cracks , for more information.
Shot Peening Machine
A shot peening procedure is necessary on some crankshafts in the bearing journal fillet areas. This procedure must be
done after the crankshaft has been straightened. Refer to SEBF8041, Crankshaft Specifications , in order to
determine which fillets need this procedure. Refer to Guideline For Reusable Parts, SEBF8094, Procedure to Grind
Crankshafts , for more information.
NOTICE
Put protection on the journals during shot peening.
Procedure To Straighten Bent Crankshaft
1. Heat the crankshaft in the oven for a minimum of 1 1/2 hours. Do not use a torch. Using a torch causes the
crankshaft to become too hot in some areas and not hot enough in others. Straighten the crankshaft when it is between
177 to 232°C (350 to 450°F).
2. Put anvils under main bearing journals, on either side of main journal to be straightened. Check for burrs on anvil
and press ram surfaces.
3. Turn crankshaft so ram can make contact at the high point (where shaft is bent the most). Put a dial indicator in
position to measure crankshaft deflection (movement from zero).
4. Put press ram carefully against main bearing journal that is to be straightened.
5. Put a small amount of pressure on the crankshaft, and release press ram. The deflection during this step must not be
more than one half of TIR measured in Procedure to Measure Used Crankshafts for Bend .
6. Check to see how much the crankshaft has been straightened. Put the contact point for the dial indicator(s) against
main bearing journals. The contact points must be to the side of the oil holes.
Turn crankshaft and look at dial indicator(s). If TIR on main bearing journals next to V-Blocks is still more than 0.13
mm (0.005 inch) [0.18 mm (0.007 inch) on 3406 Engines], put more pressure on crankshaft and increase the deflection.
Measure TIR again.
7. Increase the amount of pressure, a little at a time, until 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,
causing cracks.
8. Repeat Steps 3 through 6 to straighten any other bent areas on the crankshaft.
9. Measure the amount the crankshaft is bent according to directions in Procedure to Measure Used Crankshafts for
Bend .
10. Check the crankshaft for cracks, especially in bearing journal fillets opposite the press ram. Use magnetic crack
detection equipment. Refer to Guideline for Reusable Parts, SEBF8039, Inspection of Crankshafts for Cracks , for
more information.
Crankshaft Measurement
Preparing Crankshaft for Measurement
Illustration 16
Crankshaft installed on two 5P-8637 Support Groups (V-Blocks).
Place the crankshaft on two 5P-8637 Support Groups (V-Blocks) on a sturdy, stable work surface to hold the crankshaft
during the following procedures. Refer to Illustration 16.
Use an outside micrometer with a vernier scale and friction thimble for taking measurements. The micrometer must
have a measurement graduation of 0.001 mm (0.0001 inch).
Note: For greatest accuracy, use a precision standard, or gauge block, to adjust the micrometer before each crankshaft
is checked.
Procedure to Check Surface Finish
Illustration 17
Surface finish analyzer in use
Note: A Sclerometer should not be used on any remanufactured crankshaft that has (MHT) Melonited Heat Treat
stamped next to the 0R part number. To do so will damage the crankshaft.
The surface finish of bearing journals should be checked with a powered, surface finish analyzer that will stroke the
journal surface automatically. Refer to Illustration 17. The stylus radius must be approximately 0.013 mm (0.0005
inch) and the unit should have a 0.80 mm (0.030 inch) cutoff length.
Note: The maximum permissible surface roughness for crankshaft bearing journals is given in SEBF8041,
Crankshaft Specifications .
If the journals are rougher (have a higher number) than the specification, they must be polished. Refer to Guideline for
Reusable Parts, SEBF8042, Procedure to Polish Crankshafts .
The thrust face surface finish must be 0.45 micrometers (18 microinches) or smoother.
Make certain there are no wear steps or marks from grinding on the surface. Refer to Guideline for Reusable Parts,
SEBF8043, Visual Inspection of Crankshafts .
Surface Finish Analyzers
Surface finish analyzers are available from:
Rank Taylor-Hobson
P. O. Box 36
Guthlaxton Street
Leicester, LE2 OSP Great Britain
Telephone: 011-44-116-276-3771
Telex: 34411
Cable: Metrology Lestr
Gould Inc. Instruments Division

8333 Rockside Road
Valley View, OH 44125 U.S.A.
Phone: (216) 328-7000
Telex: 810-421-8580
Mitutoyo Manufacturing Co.

18 Essex Road
Paramus, NJ 07652 U.S.A.
Phone: (201) 368-0525

45001 5 Mile Rd.
Plymouth, MI 48170 U.S.A.
Phone: (313) 459-2810

16925 Gale Ave.
City of Industry, CA 91745 U.S.A.
Phone: (818) 961-9661

965 Corporate Blvd.
Aurora, IL 60504 U.S.A.
Phone: (708) 976-5385
Bendix, Automation and Measurement Division

721 Springfield Street
P. O. Box 1127
Dayton, OH 45401 U.S.A.
Phone: (513) 254-5377
Telex: 288031
Procedure to Check for Out-Of-Round and Diameter
Illustration 18
Measurement of journal diameter for out-of-round
Use an outside micrometer to measure the journal diameter at TDC (top dead center) and 90 degrees from TDC on rod
journals and two places, 90 degrees apart, on main journals. Refer to Illustration 18. Be sure to keep micrometer anvil
out of the oil hole and the immediate area around the oil hole where journal surface is lower.
The maximum and minimum dimensions must not be more than those found in SEBF8041, Crankshaft
Specifications . Two rod journals (or one main journal and one rod journal) can measure up to 0.005 mm (0.0002
inch) under the minimum diameter specifications shown in SEBF8041, Crankshaft Specifications .
Note: If the crankshaft has been ground undersize, subtract the amount undersize from the minimum and maximum
dimensions found in SEBF8041, Crankshaft Specifications .
Procedure to Check for Taper
Illustration 19
Measurement being taken on one side of the journal
Measure the diameter of the journal (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 in the two measurements must not be
more than that shown in the maximum taper column of the chart found in SEBF8041, Crankshaft Specifications .
Example
Main bearing journal diameter of a 2P-2842 Crankshaft on 3306 Engine:
At one fillet = 88.890 mm (3.4996 inch)
At other fillet = 88.877 mm (3.4991 inch)
Difference = 0.013 mm (0.0005 inch)
The difference is less than the use again specification of 0.015 mm (0.0006 inch) maximum taper in the chart so the
journal has an acceptable taper.
Procedure to Check for Thrust Face Wear
Illustration 20
Measurement of thrust face wear with an inside micrometer
Measure the distance between the thrust surfaces. Use a telescoping gauge and an outside or inside micrometer (shown
in Illustration 20).
The measurement between the thrust faces must be between the use again maximum and minimum dimensions with an
inside micrometer.
Note: Check for correct crankshaft endplay when the crankshaft is installed. Refer to the appropriate Service Manual
for specifications.
Procedure to Measure Profile
Illustration 21
Crankshaft ready for profile measurement.
Follow this procedure when it is necessary to take specific profile measurements.
1. The following tooling is required for this test. Refer to Illustration 21.
3P-1568 Dial Indicator, or similar indicator with 0.002 mm (0.0001 inch) accuracy.
Dial indicator base and 7H-1948 Snug (from 8S-2328 Dial Test Indicator Group).
7B-0337 Surface Plate.
Two 5P-8637 Support Groups (V-Blocks).
Note: A lug back plate can be used instead of the 7H-1948 Snug to install the indicator on the dial indicator base.
2. Put V-Blocks on a concrete floor or very rigid work surface. Put crankshaft on the V-Blocks and put a surface
plate under the journal to be measured.
3. Adjust dial indicator so the contact point will stroke (slide against) the top of the journal to be measured.
4. Adjust dial indicator to zero at the highest point of the journal diameter. Move indicator base on surface plate to
stroke the journal diameter horizontally at 3 mm (0.1 inch) intervals. Refer to Illustration 21.
Illustration 22
On the graph, 25 mm (1.0 inch) horizontal is equivalent to 5.08 mm (0.200 inch) and 25 mm (1.0 inch), and vertical is
equivalent to 0.003 mm (0.0001 inch) dial indicator reading
5. Mark the location on graph paper, of each maximum indication (reading). When all readings are taken, connect the
points on the graph paper as shown in Illustration 22.
Illustration 23
Typical example of acceptable profile: the second piece of graph paper shows all points are within 0.005 mm (0.0002
inch) width
6. Put a second sheet of graph paper over the original, refer to Illustration 23, to check that all points are within a
0.005 mm (0.0002 inch) width on the graph paper. If any points are outside this width, DO NOT use the crankshaft
again unless it is ground.
Illustration 24
Crankshaft installed between centers on a lathe with 3P-1568 Dial Test Indicator Group mounted on tool holder.
Specific profile measurements can be taken another way. This procedure is the same as the former, except the
crankshaft is put on the centers of a lathe with a 3P-1568 Dial Test Indicator Group on the tool holder. The contact
point is then adjusted to stroke the main or rod journal horizontally at 3.0 mm (0.100 inch) intervals as shown in
Illustration 24. Then use the graph procedure given in Steps 5 and 6.
Profile Measurement Equipment
Bendix, Rank Taylor-Hobson, and Federal all have electronic gauges to measure crankshaft profile. Bendix and Rank
Taylor-Hobson also have portable (can be easily moved) Profricorders, and Federal has precision airways on which a
contact point can be installed. For more information on equipment contact:
Metrology Instruments & Services,

Application Engineering Automation & Measurement Division of Bendix
P. O. Box 1127
Dayton, OH 45401 U.S.A.
Phone: (513) 254-5377
Federal Products Corporation

1144 Eddy Street
Providence, RI 02901 U.S.A.
Phone: (409) 781-9300
Federal Products Corporation Outside the U.S.
Brazil:
Federal Metrologia De Precisao Ltd.

Rue Visconde De Ouros, 367
Jardim Aeroporto
CEP 04632 Sao Paulo, S.P., Brazil
Canada:
Federal Gages Canada, Ltd.

1560 Bayview Avenue
Toronto, Ontario M4G 3B8
Great Britain:
Rank Taylor-Hobson
P. O. Box 36
Guthlaxton Street
Leicester, LE2 OSP Great Britain
Telephone: 011-44-116-276-3771
Telex: 34411
Cables: Metrology Lestr
Procedure to Check Journal Fillet Radii
There are two procedures for checking the fillet radius. The preferred method is to use the correct size gauge.
However, if the correct gauge is not available, use the Bracket-Check method.
Procedure to Check Radius with Correct Size Gauge
Follow this procedure to check crankshaft journal fillet radii after the crankshaft has been ground:
1. Use decimal radius gauges having a range of 2 to 20 mm (0.095 to 0.75 inch). Compare the profile of the gauge
with the profile of the fillet. If the gauge matches the fillet, there will be no space between the two. Refer to existing
Illustration 26. Fraction radius gauges can be used after the fractions are accurately converted to their decimal or metric
equivalents.
Note: Radius gauges in metric, inch-decimal and inch-fractions are available from:
L.S. Starrett Co.

165 Crescent St.
Athol, MA 01331-1915
2. Put the correct size gauge into the fillet. The gauge must come into contact with the center of the radius.
Illustration 25
Measurement of fillet radius
Illustration 26
Correct size gauge in full contact (A) with the fillet profile
Illustration 27
Radius is too large. Gauge is contacting radius at location (A) with the nose of the gauge only.
Illustration 28
Radius is too small. Gauge is contacting radius at location (B) with the shoulders of the gauge.
3. If the radius does not meet the specifications shown in Chart B Crankshaft Measurement Specifications , do not
use the crankshaft again.
Note: The radius dimensions given in SEBF8041, Crankshaft Specifications are before shot peening. If possible,
measure the fillets before shot peening. Refer to Guideline For Reusable Parts, SEBF8043, Visual Inspection of
Crankshafts for more information.
Procedure to Bracket-Check Journal Fillet Radii
If the exact size gauge cannot be found to measure the fillet radius, it will be necessary to bracket the fillet radius
size by using other gauges that have a larger and smaller radius than the specified fillet size. Refer to the following
example:
If SEBF8041, Crankshaft Specifications calls for a fillet radius of (0.192 inch), and that size gauge is not available,
select gauges of (0.190 inch) and (0.195 inch). Continue with Steps 2 and 3.
1. Select a gauge one size smaller than, but as close to, the specified radius. The nose of the gauge should make
contact with the contour of the fillet, as shown in Illustration 27. If the shoulders of the gauge make contact, the fillet
is larger than the gauge being used.
2. Select a gauge one size larger than, but as close to, the specified radius. The nose of the gauge should NOT make
contact with the contour of the fillet, as shown in Illustration 28. If the nose of the gauge makes contact, the fillet is
larger than the gauge being used.
3. Using the bracket-check procedure should show the actual fillet size is between the gauge sizes selected. As long
as the gauges selected are close to the specified fillet size, the crankshaft will give normal performance as long as the
crankshaft s other physical requirements are met.
Special Checking Procedure for Specific Crankshafts
The following information is used to check the radius of the rod and main fillet. This information is only used for 1W-
0400, 0R-5560, 0R-5474, and 0R-5164 Crankshafts.
Illustration 29
Check rod fillet radius

Fillet profile must fall within Zones A, B, and C.
Minimum radius in Zone C is 0.76 mm (0.030 inch).
Minimum radius in Zone B is 4.88 mm (0.192 inch)
Minimum radius in Zone A is 0.76 mm (0.030 inch), except double fillet intersection may occur in Zone A and may be
a sharp peak. (Refer to typical profile in Illustration 29).
Illustration 30
Checking main fillet radius

Fillet profile must fall within Zones A. B, and C.
Minimum radius in Zone C is 0.76 mm (0.030 inch).
Minimum radius in Zone B is 2.34 mm (0.092 inch).
Minimum radius in Zone A is 0.76 mm (0.030 inch), except double fillet intersection may occur in Zone A and may be
a sharp peak. (Refer to typical profile in Illustration 30).
Procedure to Check Journal Hardness
If a journal shows signs of high heat or grinding, it must be checked for hardness with a sclerometer, such as a 6V-6035
Hardware Tester. Only use the sclerometer since other methods may damage the crankshaft. Refer to Illustration 31.
Follow the manufacturer s recommendations for use of the sclerometer, such as a 6V-6035 Hardness Tester. The
readings must be within tolerances shown in SEBF8041, Crankshaft Specifications .
Note: At times, a soft area will be found on a journal. If this occurs, check both sides of this soft area. If the journal
hardness is within the specifications on both sides of the soft area, the journal hardness is acceptable.
Important
On some crankshafts, (the 3208 Engines and 3300 Families of Engines, for example) the rear half of the rear main
journal and the far rear fillet can be softer than the specifications shown in SEBF8041, Crankshaft Specifications .
Illustration 31
Sclerometer in use
The following companies can provide more information on portable sclerometers:
Caterpillar Service Technology Group

100 NE Adams Street
Peoria, IL 61629-9110
Phone: 1-800-542-8665 (U.S.A.)
1-800-541-8665 (Illinois)
1-800-523-8665 (Canada)
404435 (Telex)
1-309-675-6618 (FAX)
Detroit Hardness Tester

17644 Mt. Elliott Avenue
Detroit, MI 48212 U.S.A.
Phone: (313) 891-5910
Outside the United States:
Gentrex
Ford Building
Detroit, MI 48226 U.S.A.
Phone: (313) 963-3611
Telex: 235505
Note: A sclerometer should not be used on any remanufactured crankshaft that has MHT, (melonited heat treat),
stamped next to the 0R part number. To do so will damage the crankshaft.
© 2004 Caterpillar
Printed in the U.S.A
All Rights Reserved
Copyright 1993 - 2006 Caterpillar Inc. Wed Jul 12 15:05:20 UTC+0700 2006
All Rights Reserved.
Private Network For SIS Licensees.

SEBF8054 - Procedure To Measure and Straighten Bent Crankshafts

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SEBF8054 - Procedure To Measure and Straighten Bent Crankshafts

Uploaded by

Copyright:

Available Formats

3126 Industrial Engine CKK00001-UP(SEBP3371 - 12)/Basic Search Page 1 of 28

Product: INDUSTRIAL ENGINE

Reuse And Salvage Guidelines

Procedure to Measure and Straighten Bent Crankshafts

All This guideline has been revised with

Measurement information in this guideline is given in five areas:

• Procedure to measure crankshafts after the bearing journals are ground

• Procedure to determine if a bent crankshaft can be straightened

• Straightening a bent crankshaft

Tooling and Equipment

Tooling and Equipment1

7H-1942 Dial Indicator2

When replacement parts are required for this

Failure to heed this warning can lead to premature

If the crankshaft was removed from a running, assembled engine

If the crankshaft was received as a disassembled core

2. Examine the complete crankshaft for signs of rust and corrosion.

Procedure to Determine If a Crankshaft Can Be Used Again As Is

Dial indicator with contact point

Procedure for performing the measurement

Measurement of center main bearing

Measurement of TIR on Hub Circumference (1) or Flange (3) for Flywheel

Measurement of flange circumference for flywheel

Measurement of hub circumference for flywheel

3. Turn the crankshaft 360 degrees and check the TIR.

Measurement of TIR on Main Bearing Journals (4)

Measurement of TIR on Tapered Front Shaft (6)

Measurement of tapered surface

How to Prevent Axial Movement of Crankshaft

Crankshaft with steel ball pushed against heavy steel object

Procedure to Determine if a Bent Crankshaft Can Be Straightened

Straightening a Bent Crankshaft

Equipment Needed to Straighten Bent Crankshafts

Hydraulic Straightening Press

Straightening presses are available from:

Peterson Machine Tool, Inc.

Storm Vulcan, Inc.

The surfaces of the anvils and press ram that are in

Do not use anvils or press rams that are wider than

Magnetic Crack Detection Equipment

Shot Peening Machine

Put protection on the journals during shot peening.

Procedure To Straighten Bent Crankshaft

Preparing Crankshaft for Measurement

Crankshaft installed on two 5P-8637 Support Groups (V-Blocks).

Procedure to Check Surface Finish

Surface finish analyzer in use

Surface Finish Analyzers

Surface finish analyzers are available from:

Gould Inc. Instruments Division

Mitutoyo Manufacturing Co.

Mitutoyo Manufacturing Co.

Mitutoyo Manufacturing Co.

Mitutoyo Manufacturing Co.

Bendix, Automation and Measurement Division

Procedure to Check for Out-Of-Round and Diameter

Measurement of journal diameter for out-of-round

Procedure to Check for Taper

Measurement being taken on one side of the journal

Main bearing journal diameter of a 2P-2842 Crankshaft on 3306 Engine:

At one fillet = 88.890 mm (3.4996 inch)

At other fillet = 88.877 mm (3.4991 inch)

Difference = 0.013 mm (0.0005 inch)