SEBF8054 - Procedure To Measure and To Straighten Bent Crankshafts (0760, 1202) PDF

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BsquedadelmedioSEBF8054ProceduretoMeasureandtoStraightenBentCrankshafts{0760,1202}
Pantallaanterior
Bienvenido:r080am5
Producto:NOSEHAESCOGIDONINGUNEQUIPO
Modelo:NOSEHAESCOGIDONINGUNEQUIPO
Configuracin:NOSEHAESCOGIDONINGUNEQUIPO
Pautasdereutilizacinyrecuperacin
ProceduretoMeasureandtoStraightenBentCrankshafts{0760,1202}
NmerodemedioSEBF805430
Caterpillar:ConfidentialYellow
Fechadepublicacin13/01/2015
Fechadeactualizacin29/04/2016
i06688203
ProceduretoMeasureandtoStraightenBentCrankshafts{0760,1202}
SMCS07601202
CaterpillarProducts
All
Introduction
Table1
Revision
SummaryofChangesinSEBF8054
2730
Addednewserialnumberprefixes.
26
Correctedsupportplacementin1for"MeasurementofTIRonHubCircumferenceorFlangefor
Flywheel"section.
25
UpdatedEffectivity
24
UpdatedEffectivity
Added"ImportantSafetyInformation"section.
23
Removedrestrictionon3500andC175salvageprocedures.
Correctedtemperatureheatingvalues.
CorrectedtitleforSEBF8041
2016CaterpillarAllRightsReserved.ThisguidelineisfortheuseofCatdealersonly.Unauthorizeduseofthis
documentortheproprietaryprocessesthereinwithoutpermissionmaybeviolationofintellectualpropertylaw.
InformationcontainedinthisdocumentisconsideredCaterpillar:ConfidentialYellow.
ThisReuseandSalvageGuidelinecontainsthenecessaryinformationtoallowadealertoestablishaparts
reusabilityprogram.ReuseandsalvageinformationenablesCaterpillardealersandcustomerstobenefitfromcost
reductions.EveryefforthasbeenmadetoprovidethemostcurrentinformationthatisknowntoCaterpillar.
Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyourproductwhich
r080am5
arenotincludedinthispublication.ThisReuseandSalvageGuidelinemustbeusedwiththelatesttechnical
informationthatisavailablefromCaterpillar.
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Forquestionsoradditionalinformationconcerningthisguideline,submitaformforfeedbackintheService
InformationSystem.Toaddressanurgentissue,usethefollowingresourcestocommunicateyourrequestto
CaterpillarRepairProcessEngineering:
CaterpillarDealerTechnicalCommunicator
DealerSolutionNetwork
CaterpillarTechnicalRepresentative
KnowledgeNetwork
CanceledPartNumbersandReplacedPartNumbers
Thisdocumentmaynotincludecanceledpartnumbersandreplacedpartnumbers.UseNPRonSISfor
informationaboutcanceledpartnumbersandreplacedpartnumbers.NPRwillprovidethecurrentpartnumbers
forreplacedparts.
ImportantSafetyInformation
Illustration1
g02139237
Worksafely.Mostaccidentsthatinvolveproductoperation,maintenance,andrepairarecausedbyfailureto
observebasicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentiallyhazardous
situationsbeforeanaccidentoccurs.Apersonmustbealerttopotentialhazards.Thispersonshouldalsohavethe
necessarytraining,skills,andtoolstoperformthesefunctionsproperly.Safetyprecautionsandwarningsare
providedinthisinstructionandontheproduct.Ifthesehazardwarningsarenotheeded,bodilyinjuryordeath
couldoccurtoyouortootherpersons.Caterpillarcannotanticipateeverypossiblecircumstancethatmightinvolve
apotentialhazard.Therefore,thewarningsinthispublicationandthewarningsthatareontheproductarenotall
inclusive.Ifatool,aprocedure,aworkmethod,oroperatingtechniquethatisnotspecificallyrecommendedby
Caterpillarisused,ensurethatitissafeforyouandforotherpeopletouse.Ensurethattheproductwillnotbe
damagedortheproductwillnotbemadeunsafebytheoperation,lubrication,maintenance,ortherepair
proceduresthatareused.
Improperoperation,lubrication,maintenanceorrepairofthisproduct
canbedangerousandcouldresultininjuryordeath.
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Donotoperateorperformanylubrication,maintenanceorrepairon
thisproduct,untilyouhavereadandunderstoodtheoperation,
lubrication,maintenanceandrepairinformation.
Safetyprecautionsandwarningsareprovidedinthismanualandontheproduct.Ifthesehazardwarningsarenot
heeded,bodilyinjuryordeathcouldoccurtoyouortootherpersons.
Thehazardsareidentifiedbythesafetyalertsymbolwhichisfollowedbyasignalwordsuchasdanger,warning,
orcaution.The"WARNING"safetyalertsymbolisshownbelow.
Illustration2
g00008666
Thissafetyalertsymbolmeans:
Payattention!
Becomealert!
Yoursafetyisinvolved.
Themessagethatappearsunderthesafetyalertsymbolexplainsthehazard.
Operationsthatmaycauseproductdamageareidentifiedby"NOTICE"labelsontheproductandinthis
publication.
Caterpillarcannotanticipateeverypossiblecircumstancethatmightinvolveapotentialhazard.Thesafety
informationinthisdocumentandthesafetyinformationonthemachinearenotallinclusive.Determine
thatthetools,procedures,workmethods,andoperatingtechniquesaresafe.Determinethattheoperation,
lubrication,maintenance,andrepairprocedureswillnotdamagethemachine.Also,determinethatthe
operation,lubrication,maintenance,andrepairprocedureswillnotmakethemachineunsafe.
Theinformation,thespecifications,andtheillustrationsthatexistinthisguidelinearebasedoninformationwhich
wasavailableatthetimeofpublication.Thespecifications,torques,pressures,measurements,adjustments,
illustrations,andotheritemscanchangeatanytime.Thesechangescanaffecttheservicethatisgiventothe
product.Obtainthecomplete,mostcurrentinformationbeforeyoustartanyjob.Caterpillardealerscansupplythe
mostcurrentinformation.
Summary
Thejournalsonausedcrankshaftmustbecheckedforsize,roundness,straightness,wearonthethrustface,and
thesurfacefinish.Ifthecrankshaftisgroundundersize,thenlobing,radius,straightness,andhardnessofthe
journalmustalsobechecked.
Thisguidelinegivestheprocedureformeasuringandstraighteningofcrankshafts.Ifacrankshaftmeetsthe
specificationsfoundinthisguideline,thenthecrankshaftcanbeexpectedperformnormallyuntilthenextoverhaul
whenthecrankshaftisusedagaininthesameapplication.
Somebentcrankshaftscanbeusedagainifthecrankshaftisproperlystraightened.Measuringthecrankshaft
carefullyisthefirststepinthesalvageprocedure.
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RefertotheappropriatespecificationReuseandSalvageGuidelineforthemeasurementsthecrankshaft.Referto
the"References"sectionfoundwithinthisdocumentforalistofspecificationReuseandSalvageGuidelines.The
crankshaftcanbeusedagainifthemeasurementsaremet.
Note:CrankshaftsfromC9,C10,C11,C12,C13,andC15seriesenginesshouldnotbestraightened.Ifthe
crankshaftfromanyoftheseenginesarebentmorethantheallowablespecificationslisted,thenthecrankshaft
shouldbereplaced.
References
Reference:ReuseandSalvageGuideline,SEBF8039,"CrankshaftVisualInspectionandMagneticParticle
Inspection".
Reference:ReuseandSalvageGuideline,SEBF8042,"ProcedureforGrindingandPolishingtheCrankshaft".
Reference:ReuseandSalvageGuideline,SEBF9217,"SpecificationsforCrankshaftsinC7,C9,C9,C10,C11,
C12,C12,C13,C13,C15,C15,C16,C16,C18,C18,C27,C30,andC32Engines".
Reference:ReuseandSalvageGuideline,SEBF9220,"SpecificationsforCrankshaftsin3400,3300,3200,3100,
3000,andDseriesEngines".
Reference:ReuseandSalvageGuideline,SEBF8041,"SpecificationsforCrankshaftsin3500Engines".
Reference:ReuseandSalvageGuideline,SEBF9184,"SpecificationsandMeasuringProceduresforCrankshafts
inC175Engines".
Reference:ReuseandSalvageGuideline,SEBF8102,"SpecificationsforCrankshaftsin3600andC280Series
Engines".
ToolingandEquipment
Table2
ToolingandEquipment
PartNumber
PartDescription
8T5096
DialIndicatorTestGroup
5P4163
IndicatorContactPoint
5P8637
Supports(VBlocks)
6V7926
DialIndicatorGroup
7B0337
SurfacePlate
HardnessTester
7H1940
UniversalAttachment
3P1568
DialIndicator
7H1941
DialIndicatorBase
7H1948
SwivelPost
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RadiusGauges
AirGauges
CrankshaftInspection
Performthefollowingcheckstoconfirmthereusabilityofthecrankshaft.
Note:RefertoReuseandSalvageGuideline,SEBF8039,"CrankshaftVisualInspectionandMagneticParticle
Inspection"forcrankshaftinspection.
Thefollowingvisualchecksmustbeperformedinitially.Thesecheckswilldetermineifthecrankshaftisreusable
earlyintheprocesswithoutwastingvaluabletime.
1.Examineallsurfacesofthecrankshaftfordiscolorationcausedbyexcessiveheat.Donotreuseanyparts
thathavebeenremovedfromanenginewhichwasinvolvedinafire.
2.Examinetheexteriorsurfacesofthecrankshaftforphysicaldamagesuchasnicks,dents,andlargecracks.
3.Examinetherodandthemainbearingjournalsfor:
Deepscratches.
Cracksinthefillets.
Thetransferofmetalduetolackoflubrication.
Evidenceofdamageduetoimpropergroundingduringwelding.
4.Checkforsignsofrustandcorrosion.
5.Thecrankshaftmustbecorrectfortheintendedengineapplication.Thecrankshaftmustalsobeagenuine
Catproduct.
Note:Crankshaftsthathavebeenregroundformarineenginesarenotapprovedbysomemarinecertification
societiesandbysomeinsurancecompanies.Contacttheinsurancecompanyorarepresentativefromthemarine
certificationsocietyforacceptabilityofcrankshaftsthathavebeenreground.
ProceduretoMeasureUsedCrankshaftsforBend
ToolingSetup
Illustration3
g01452598
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6V7926DialIndicatorGroup
Usethe6V7926DialIndicatorGroupforallmeasurements.
Illustration4
g03082281
Typicalairgaugeandcalibrationblocksusedforcrankshaftmeasurement.
Illustration5
g03102678
Airgaugetoolingproperlysetup.
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Illustration6
g03061140
5P8637Supports
Illustration7
g03081059
Crankshaftsupportwithrollers.
CrankshaftsupportsaresometimesreferredtoasVblocks.
Placetwocrankshaftsupportsonamachinedgraniteslab,asurfaceplate,oraconcretefloor.Donotuseawork
bench.Theweightofthecrankshaftmaybendtheworkbenchresultingininaccuratemeasurements.
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Illustration8
g01452608
Themagneticbaseofthedialindicatormustbeheldstationarywithapieceofsteelwiththreepadsweldedtothebottom.
Useapieceofsteeltoholdthemagneticbaseforthedialindicator.Weldthreeidenticalsteelpads120degrees
aparttothebottomofapieceofsteel.
1.Thecrankshaftsupportsshouldbealignedbeforeandafterthecrankshafthasbeenplacedonthesupports.
Alignthecrankshaftsupportssuchthatbothbasesareanequaldistancefromanestablishedreferencepoint.
Asecuredmetalstripthatisparalleltotheedgeofasurfaceplateorabluelineonconcretearegood
referencepoints.
Illustration9
g02197254
Positionthecrankshaftsupportsunderneaththemainjournalbearingsattheendsofthecrankshaft.
2.Placethecrankshaftwiththecrankshaftsupportsunderneaththemainjournalsattheendsofthecrankshaft.
RefertoIllustration9.Checkthecrankshaftsupportsandthecrankshafttoensurethatthesupportsare
stationaryandaligned.Thecrankshaftmustrotateinthesupports,butnotmovehorizontally.
Note:Ensurethattheoilholedoesnotcomeincontactwiththecenterofthecrankshaftsupport.When
possible,keepthecrankshaftsupporttoonesideofthecrankshaftjournalbutnotintothefillet.The
diameterofthecrankshaftjournalshouldbetheonlypointofcontactwiththecrankshaftsupport.
Note:UsethesamereferencepointusedinStep2toalignthebaseofthedialindicator.Usingthisreference
pointwillensureamoreefficientprocedureforsetupandinspection.
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Illustration10
g02197316
The5P8637Supportsarepositionedunderthemainjournalbearingsontheendofthecrankshaft
3.Placethemagneticbaseofthedialindicatoronthepieceofsteel.Putthecontactpointforthedialindicator
ononeofthemainjournalsthatarenexttoacrankshaftsupport.RefertoIllustration10.Positionthedial
indicatorsothestemwillnotcontacttheoilhole.Thecontactpointmustbeperpendiculartothebearing
surface.
4.Oncetheadjustmentsaremade,rotatethecrankshaft360degreestoensurethatthetravelofthedial
indicatorissufficient.Adjustthedialindicatortozero.
Note:Thisproceduremustbeperformedeverytimethecrankshaftsupportshavebeenmoved.
ProcedureforPerformingtheMeasurement
Theproceduretobedescribedisreferredtoasthestepinmethod.Thisspecificexampleisforacrankshaftwith
sevenjournals,butthebasicprincipleappliestoallcrankshafts.
Table3
ExampleVBlockandMeasurementPositioningfora16CylinderEngine
VBlockJournalPosition
Journalbeingmeasured
1and9
2and8
2and8
3and7
3and7
4and6
4and6
Onallcrankshafts,startbyplacingthe5P8637Supportsonthefarthestoutsidemainjournalsandworkinward.
TaketheTotalIndicatorRunout(TIR)measurementonthenextinteriormainbearingjournalsdirectlynexttothe
crankshaftsupports.DonotattemptanyadditionalTIRmeasurementsonotherjournalsatthistime.Forexample:
Ifthecrankshaftsupportsareonjournals1and7,thenonlyjournals2and6willbemeasured.Whenthe
crankshaftsupportsarelocatedonjournals3and5,onlyjournal4willbemeasured.RefertoTable3foran r080am5
example.
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IfyouattempttorecordtheTIRforjournalnumber4whenthecrankshaftsupportsarepositionedatjournals
number1and7(or2and6),youwilltakeaninaccuratemeasurementbecauseofsagatthecenterofthe
crankshaft.(Thesameistruewhenthecrankshaftsupportsarelocatedonjournals3and5andyouattemptto
measurejournals1and7.)
Note:The3406,3456,C15,andC18crankshaftshaveadifferentTIRthanothercrankshaftsandhavedifferent
considerationsforcheckingforstraightness.Referto"SpecialConsiderationsfor3406,3456,C15,andC18
crankshafts"laterinthisdocument.
Note:Assumethatthetoolingwassetuponthemainjournal.
Illustration11
g02184335
5P8637Supportsonjournals1and7whilemeasuringTIRofjournals2and6
1.Positiononesupportundereachmainjournalonthefarendsofthecrankshaft.RefertoIllustration11,the
crankshaftsupportsarelocatedonthemainjournals1and7.
2.Withthedialindicatorsetuponjournalnumber2,rotatethecrankshaft360degreesandrecordtheTotal
IndicatedRunout(TIR).TheTIRisthedifferencebetweenthehighestreadingsandthelowestreadingson
thedialindicatorwhilethecrankshaftisbeingrotated.
Note:Ifanoilholecomesincontactwithacrankshaftsupport,theTIRwillbeincorrect.Trytokeepthe
crankshaftsupportstoonesideofthecrankshaftjournal,butnotintothefillet,sothediameterofthe
crankshaftjournalistheonlypointofcontactwiththecrankshaftsupport.
3.Movethedialindicatortojournalnumber6,andzerothedialindicatoragain.Rotatethecrankshaft360
degreesandrecordtheTIR
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Illustration12
g02184456
5P8637Supportsonmainjournals2and6whilemeasuringTIRofjournals3and5
4.Movethecrankshaftsupportstowardsthecenterofthecrankshaftonejournaltothemainjournals2and6.
RefertoIllustration12.
5.Positionthedialindicatoronjournalnumber3andzerothedialindicator.Rotatethecrankshaft360degrees
andrecordthetotalTIR.Repeatthisstepforjournalnumber5.
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Illustration13
g02184473
5P8637Supportsonmainjournals3and5whilemeasuringTIRofjournal4
6.Movethecrankshaftsupportstowardsthecenterofthecrankshaftonejournaltothemainjournals3and5.
RefertoIllustration13.
7.Positionthedialindicatoronjournal4andzerothedialindicator.Rotatethecrankshaft360degreesand
recordthetotalTIR.
Note:IftherearetwomaximumpointsduringthemeasurementofTIR,useanoutsidemicrometer.Checkforan
outofroundmainjournal.
SpecialConsiderationsfor3406,3456,C15,andC18crankshafts
Adifferentmeasuringproceduremustbeusedforthe3406,3456,C15,andC18crankshafts.Thesecrankshafts
willuseanadjacentjournalcheckandastackuptolerancecheck.YouwillbetakingaTIRreadingonmain
bearingjournalnumber4ineachcheck.IftheTIRreadingsonbothchecksarewithinspecificationsthatarelisted,
thecrankshaftisgood.
AdjacentJournalCheck
Illustration14
g02256293
Adjacentjournalreadingofmainbearingnumber4withthecrankshaftsupportsonjournals3and5
Theadjacentjournalcheckshouldbeperformedwiththecrankshaftsupportspositionedonmainbearingjournals
3and5.PerformtheTIRreadingonmainbearingjournalnumber4only.TheTIRonmainbearingjournal
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number4shouldnotexceed0.18mm(0.007inch).
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StackUpToleranceCheck
Illustration15
g02193660
StackupTIRreadingonmainbearingjournalnumber4
Thischeckshouldbeperformedwiththecrankshaftsupportspositionedonmainbearingjournals1and7.The
TIRshouldbemeasuredonbearingjournalnumber4only.TheTIRonjournalnumber4shouldnotexceed
0.54mm(0.021inch).
ProceduretoMeasureCrankshaftsaftertheBearingJournalshave
beenGround
Ifacrankshaftisreground,journalsmustbeinalignmentwithothersurfacesofthecrankshaft.TheTIRforanyof
themeasurementsthatfollowcannotbemorethanspecificationsfoundintheReuseandSalvageGuideline
specificationsfortherespectiveengineplatform.Refertothe"References"sectionfoundwithinthisdocumentfor
alistofspecificationReuseandSalvageGuidelines.Thecrankshaftcannotbeusedagainifthemeasurementsare
greaterthanspecifications.Grindthecrankshafttothenextstandardsizeandthenmeasurethecrankshaftagain.
MeasurementofTIRonHubCircumferenceorFlangeforFlywheel
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Illustration16
g03060097
1.Putthecrankshaftsupportsunderthenumbertwoandsixmainjournals.Putthecontactpointofthedial
indicatoronthecircumferenceoftheflywheelpilot.RefertoIllustration16.
Note:Thecontactpointmustnotbeintheweargrooveoftherearcrankshaftseal.
Measuringthecircumferenceofthefrontflange.
Illustration17
g01394439
MeasuringTIR
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Illustration18
g02300094
MeasuringTIR
2.Thecontactpointmustbeperpendiculartothesurfaceandattheapproximatecenterlineofthecrankshaft.
Forallengineswithapilothubfortheflywheel,putthecontactpointforthedialindicatoronthehubofthe
crankshaft.RefertoIllustrations17and18.
3.Turnthecrankshaft360degreesandcheckTIR.
MeasurementofTIRonFlangeforPulleyorDamperandFlywheel
Illustration19
g01394669
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Themeasurementoftheflangefaceforapulleyoradamperonalathe.Themeasurementcanalsobemadeusing5P8637Supportsifa
latheisnotavailable.
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Referto"PreventingAxialMovementoftheCrankshaft"sectionofthisguideline.Removethe5P4163Indicator
ContactPoint.Installthe7H1940UniversalAttachmenttothedialindicator.Putthepointfortheuniversal
attachmentonthefaceoftheflangeforthepulleyorthedamper.RefertoIllustration21.Thepointofthe
universalattachmentmustbeneartheoutercircumferenceoftheflangefacesothatthepointwillnothittheholes
inthecrankshaft.Turnthecrankshaft360degreesandcheckTIR.Usethesameprocedureforthefaceofthe
flywheelflange.
MeasurementofTIRonMainBearingJournals
Measurethemainbearingjournals.Referto"ProceduretoMeasureUsedCrankshaftsforBend"sectionofthis
guideline.ThemaximumTIRspecificationforthemainbearingjournalsofmostregroundcrankshaftsis0.13mm
(0.005inch).ThemaximumTIRspecificationforthemainbearingjournalsfor3406,3456,C15,andC18
crankshaftsis0.18mm(0.007inch).
MeasurementofTIRonFrontFlange,StraightFrontShaft,orHub
Circumference
Performthestepsoutlinedunder"MeasurementofTIRonHubCircumferenceorFlangeforFlywheel"sectionof
thisguidelinetochecktheTIRonthefrontflange,thestraightfrontshaft,orthehubcircumference.Thecontact
pointmustbeperpendiculartothesurfaceandattheapproximatecenterlineofthecrankshaft.Turnthecrankshaft
360degreesandcheckTIR.Donotallowthecontactpointtohitakeyway.
MeasurementofTIRonTaperedFrontShaft
Illustration20
g01394721
Measuringthetaperedsurface
Referto"PreventingAxialMovementoftheCrankshaft"sectionofthisguideline.Putthecontactpointforthedial
indicatorneartheendofthetaperedsurface.RefertoIllustration20.Thecontactpointmustbeperpendicularto
thetaperedsurfaceandattheapproximatecenterlineofthecrankshaft.Turnthecrankshaft360degreesandcheck
TIR.Donotallowthecontactpointtohitakeyway.
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PreventingAxialMovementoftheCrankshaft
Theremainderofthemeasurementscanonlybedonewithaccuracyifallaxialmovementofthecrankshaftis
prevented.Onemethodisinstallingsmallercrankshaftsandmediumcrankshaftsonalatheinthecenterofthe
crankshaft.
Note:DonotusealathetocheckTIRofthemainbearingjournalsofalargecrankshaft.Theweightofthe
crankshaftcancauseanincorrectTIR.
Illustration21
g01394835
Crankshaftwithasteelballthatispushedagainstaheavysteelobject
Asecondmethodisbyusingsupportswithahardenedsteelballthathasthediameterof19.7mmto22.4mm
(0.62inchto0.88inch).Putthesteelballinamachinedcenteronthefrontendofacrankshaft.Pushthe
crankshaftandthesteelballagainstaheavysteelobject.RefertoIllustration21.Putoilonthesteelball.Donot
moveordenttheheavysteelobjectwhenpressureisapplied.Thecrankshaftmustbeheldagainstthesteelobject
whilethemeasurementsaretaken.
DetermineifaBentCrankshaftCanBeStraightened
Note:CrankshaftsfromC9,C10,C11,C12,C13,andC15seriesenginesshouldnotbestraightened.Ifthe
crankshaftsfromtheseenginesarebentmorethantheallowablespecificationsthatarelisted,thenthecrankshaft
shouldbereplaced.
FollowthisproceduretomeasuretheoverallTIRatthecentermainbearing.
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Illustration22
g01395047
Thecrankshaftisinstalledonsupports.MeasuretheTIRatthecentermainjournalbearingonly.Thismeasurementwilldetermineif
thecrankshaftcanbestraightenedsafely.
1.Performsteps1through4of"ToolingSetup"sectionofthisguideline.
2.Placethecontactpointforthedialindicatoronthecentermainbearing.RefertoIllustration22.Thecontact
pointmustbetothesideoftheoilhole,perpendiculartothebearingsurface,andattheapproximate
centerlineofthecrankshaft.
3.Rotatethecrankshaftto360degreesaftertheadjustmentshavebeenmade.Movingthecrankshaftensures
thatthereissufficienttravelforthedialindicator.Adjustthedialindicatortozero.
4.Turnthecrankshaft360degreesandcheckthedialindicator.MakeanoteofTIR.
5.ThecrankshaftcanbestraightenedifTIRiswithinthespecificationsfoundwithintheappropriate
specificationReuseandSalvageGuideline.Refertothe"References"sectionfoundwithinthisdocumentfor
alistofspecificationReuseandSalvageGuidelines.
StraighteningaBentCrankshaft
CrankshaftsfromC9,C10,C11,C12,C13,andC15seriesenginesshouldnotbestraightened.Ifthecrankshafts
fromtheseenginesarebentmorethantheallowablespecificationsthatarelisted,thenthecrankshaftshouldbe
replaced.
Grindingthebearingsurfacesisonemethodthatisusedtostraightenbentcrankshafts.Althoughgrindingthe
surfacesiseasier,grindingislimitedbecausethebearingsurfacesmustbecompletelyground.Thefinishedsize
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EquipmentNeededtoStraightenBentCrankshafts
Oven
Heatingthecrankshaftwithanoveniscrucial.Theovenmustheatthecrankshaftto177to232C
(350to450F).Topreventcracks,donotstraightenthecrankshaftatroomtemperature.Temperatureofthe
crankshaftcanbemeasuredwitha1643310InfraredThermometer.Thetemperaturecanalsobecheckedwith
temperaturerecordingcrayons.
HydraulicPressforStraightening
Ahydraulicpressisnecessarytostraightenthecrankshaft.Thepressmustbeequippedwithoneormoredial
indicatorstomeasureTIRonthemainbearingjournalswhilethecrankshaftisinthepress.
Hydraulicpressesareavailablefromthefollowingcorporations.
EitelPressesInc.
97PinedaleIndustrialRoad
Orwigsburg,PA17961
http://www.eitelpresses.com/
Phone5703660585
Fax5703662536
DakeCorporation
724RobbinsRad
GrandHaven,MI49417
http://www.dakecorp.com/
Phone8009373253
Fax8008463253
NOTICE
Topreventdamagetothecrankshaft,theanvilandtherammustbe
madefromsoftsteelorcopperandnarrowerthanthebearingjournal.
Theuseofananviloraramthatiswiderthanthebearingjournalcan
damagethefillet.DonotuseCrankshaftSupportsasasupportfor
straighteningthecrankshaft.
EquipmentforMagneticParticleInspection
Acrankshaftthathasbeenstraightenedmustbecheckedforcracks.Themagneticparticleproceduremustbeused
afterstraighteningthecrankshaft.
RefertoReuseandSalvageGuideline,SEBF8039,"CrankshaftVisualInspectionandMagneticParticle
Inspection".
MachineforShotPeening
Shotpeeningthefilletofthebearingjournalonsomecrankshaftsmaybenecessary.Thisproceduremustbedone
afterthecrankshafthasbeenstraightened.RefertotheappropriateReuseandSalvageGuidelinespecifications,
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ReuseandSalvageGuideline,SEBF8042,"ProcedureforGrindingandPolishingtheCrankshaft"andReuseand
SalvageGuideline,SEBF9134,"ProceduretoShotPeen3512,3516,and3524HighDisplacementCrankshafts".
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ProceduretoStraightenBentCrankshafts
NOTICE
Thisprocedureisnotapplicableformicroalloyedcrankshafts.
1.Heatthecrankshaftintheovenforaminimumof11/2hours.Donotuseatorch.Atorchdoesnotproduce
anevenheat.Straightenthecrankshaftwhenthetemperatureisbetween177Cto232C(350Fto450F).
2.Putanvilsoneachsideofthemainjournalthatwillbestraightened.Checkforburrsontheanvilandthe
surfacesoftheram.
3.Turnthecrankshaftsothattheramcanmakecontactatthehighpoint.Putadialindicatorinpositionto
measurethedeflectionofthecrankshaft.
4.Carefullyputtheramagainstthemainjournalthatwillbestraightened.
5.Putasmallamountofpressureonthecrankshaftandreleasetheram.Thedeflectionduringthisstepmust
notbemorethanonehalfoftheTIRmeasuredin"ProceduretoMeasureUsedCrankshaftsforBend"
sectionofthisguideline.
6.Checkthestraightnessofthecrankshaft.Putthecontactpointforthedialindicatoragainstthemainbearing
journals.Thecontactpointsmustbetothesideoftheoilholes.Turnthecrankshaftandlookatthedial
indicator.ApplymorepressureandincreasethedeflectioniftheTIRonthemainbearingjournalsnextto
theCrankshaftSupportsismorethan0.13mm(0.005inch).TheTIRfor3406,3456,C15,andC18
crankshaftsmustnotbemorethan0.18mm(0.007inch).Afterincreasingthedeflection,measurethe
TIRagain.
7.Increasetheamountofpressureinsmallincrements,untiltheTIRonthisjournalmeetsthespecifications.
Becarefulnottousetoomuchpressuresinceexcessivepressurecancausethecrankshafttobendinthe
oppositedirection.Crackswilloccurifthecrankshaftisbentintheoppositedirection.
8.Repeatstep3through6tostraightenanyotherbentareasonthecrankshaft.
9.Measuretheamountofbendinthecrankshaftaccordingtothedirectionsin"ProceduretoMeasureUsed
CrankshaftsforBend"sectionofthisguideline.
10.Checkthecrankshaftforcracks.Especiallycheckthefilletsofthejournalontheoppositesideoftheram.
Usethemagneticparticleinspection.RefertoReuseandSalvageGuideline,SEBF8039,"CrankshaftVisual
InspectionandMagneticParticleInspection".
CrankshaftMeasurement
PreparingforCrankshaftMeasurement
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Illustration23
g03060262
Acrankshaftinstalledonthree5P8637Supports.
Placethecrankshaftonaminimumofthreesupports.Placetwosupportsoneachendandatleastoneatthecenter
ofthecrankshafttoeliminatesag.RefertoIllustration23.Theblocksshouldbeonasturdyworksurfacetohold
thecrankshaftduringthefollowingprocedures.
Useanairgaugefortakingmeasurements.Ifanairgaugeisnotavailable,thenanoutsidemicrometerwitha
vernierscaleandafrictionthimblemustbeused.Themicrometermusthaveagraduationof0.001mm
(0.0001inch).Forgreatestaccuracy,useagaugeblocktoadjustthemicrometerbeforeeachcrankshaftischecked.
ProceduretoCheckforOutOfRoundandDiameter
Illustration24
g01396635
Measuringforoutofroundofthejournaldiameter
1.Airgaugesarethepreferredtoolinghowever,outsidemicrometersareacceptable.Measuretherodsand
mainsjournaldiameterattopdeadcenterTDC.
2.Measuretherodandmainjournals90degreesfromTDC.RefertoIllustration24.
3.Besuretokeepthetoolingoutoftheoilholeandtheimmediateareaaroundtheoilholewherethejournal
surfaceislower.
ThedimensionsmustbenogreaterthanthespecificationsfoundintheReuseandSalvageGuidelinespecifications
fortherespectiveengineplatform.Thediameteroftworodjournalscanbe0.005mm(0.0002inch)underthe
minimumspecificationsthatareshownintheappropriatespecificationReuseandSalvageGuideline.Refertothe
"References"sectionfoundwithinthisdocumentforalistofspecificationReuseandSalvageGuidelines.
Note:Ifthecrankshafthasbeengroundundersize,subtracttheundersizedimensionofthecrankshaftfromthe
minimumormaximumdimensions.RefertotheReuseandSalvageGuidelinespecificationsfortherespective
engineplatformforthecorrectdimensions.
ProceduretoCheckforTaper
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Illustration25
g01397503
Takingthemeasurementononesideofthejournal
Airgaugesarethetoolingformeasuring,howeveroutsidemicrometerswithagraduationof0.001mm
(0.00004inch)areacceptable.MeasurethediameteroftherodjournalatTDCnexttobutnotoneachfillet.
Measurementsmustbetakenonbothsidesofthejournal.RefertoIllustration25.Thedifferenceofthetwo
measurementsmustnotexceedthedimensionsoftaper.RefertotheReuseandSalvageGuidelinespecifications
fortherespectiveengineplatformforspecificationsoftaper.Refertothe"References"sectionfoundwithinthis
documentforalistofspecificationReuseandSalvageGuidelines.
Example
Thediameterofthemainbearingjournalofa2P2842Crankshaftona3306Engine
Table4
3306Crankshaft
Onefillet
88.890mm(3.4996inch)
Otherfillet 88.877mm(3.4991inch)
Difference
0.013mm(0.0005inch)
Thedifferenceislessthanthereusablespecificationof0.015mm(0.0006inch)formaximumtaper.Thejournal
hasacceptabletaper.
ProceduretoCheckforWearoftheThrustFace
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Illustration26
g01397566
Measuringthewearofthethrustfacewithamicrometer
Illustration27
g02300475
Thedistancebetweenthrustsurfacesthatshouldbemeasured
Useaninsidemicrometer.Measurethedistancebetweenthethrustsurfaces.RefertoIllustration26.The
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Note:Whenthecrankshaftisinstalled,checkforthecorrectcrankshaftendplay.RefertotheReuseandSalvage
Guidelinespecificationsfortherespectiveengineplatformforendplayspecifications.Refertothe"References"
sectionfoundwithinthisdocumentforalistofspecificationReuseandSalvageGuidelines.
ProceduretoCheckJournalStraightness
Followthisprocedurewhenspecificmeasurementsofjournalstraightnessarenecessary.Thefollowingtoolingis
requiredforthistest.RefertoIllustration29.
Table5
ToolingforMeasuringProfile
3P1568DialIndicatororasimilarindicatorwiththeaccuracyof0.002mm(0.0001inch)
7H1941DialIndicatorBaseand7H1948SwivelPostSnug
Bothpartsareincludedinthe8S2328DialIndicatorGroup.
7B0337SurfacePlate
5P8637VeeBlocks
Illustration28
g03103438
Crankshaftsupportsonamachinedgraniteslabalignedwithamachinedstraightedge.
1.Putthecrankshaftsupportsonaconcretefloor,asturdysurface,orpreferablyamachinedgraniteslab.Refer
toIllustration28.
2.Alignthecrankshaftsupportswithamachinedstraightedgeandplacethecrankshaftonthesupports.Ensure
thatthecrankshaftisfullysupportedtoeliminateanyeffectsofsagging.Putasurfaceplateunderthejournal
thatwillbemeasured.
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Illustration29
g01397606
Measuringtheprofileofthecrankshaft
3.Adjustthedialindicatorsothecontactpointwillslideagainstthetopofthejournalthatwillbemeasured.
4.Adjustthedialindicatortozeroatthehighestpointofthejournaldiameter.Movethedialindicatorbaseon
thesurfaceplatetostrokethejournaldiameterhorizontallyatintervalsof3mm(0.1inch).Referto
Illustration32.
Illustration30
g03090220
5.Markthelocationofeachmaximumindicationreadingongraphpaper.Whenallthereadingsaretaken,
connectthepointsonthegraphpaper.RefertoIllustration30.
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Illustration31
g03060580
Thegraphisacceptablebecauseallpointsarewithinthewidthof0.005mm(0.0002inch).
6.Placeasecondsheetofgraphpaperovertheoriginalpiecetocheckthatallthepointsarewithinthewidthof
0.005mm(0.0002inch).RefertoIllustration31.Ifanypointsareoutsidethiswidth,donotusethe
crankshaftagainunlessthecrankshafthasbeenground.
Illustration32
g01398278
Thecrankshaftisinstalledbetweencentersonalathe.A3P1568DialIndicatorismountedonthetoolholder.
Useadditionalcrankshaftsupportstosupportthecenterofthecrankshaftasneeded.
Specificmeasurementsofthejournalprofilecanbetakenbyusingbothprocedures.Theproceduresforcheckinga
journaltaperandprofileareverysimilar.Thedifferenceisplacingthecrankshaftsonthecentersofalatheinstead
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ofsupports.A3P1568DialIndicatorismountedonthetoolholder.Thecontactpointisthenadjustedtoslide
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againstthemainjournalortherodjournalhorizontallyat3.0mm(0.12inch)intervals.RefertoIllustration32.
Repeatthecheckingfortaperproceduresteps5and6.
EquipmentneededtoMeasuretheProfile
Severalcompaniesmakeequipmentformeasuringtheprofile.
TaylorHobsonLtd
POBox36
2NewStarRoad
Leicester,LE49JQ,England
www.taylorhobson.com
Phone44(0)1162763771
Fax44(0)1162460579
MahrFederalInc
1144EddyStreet
Providence,RI02905
USA
http://www.mahrfederal.com
Phone18003432050
Fax1(401)7843246
ProceduretoChecktheFilletoftheJournal
Therearetwoproceduresforcheckingtheradiusofthefillet.Usingthecorrectsizeofgaugesisthepreferred
method.Usethebracketcheckmethodifthecorrectgaugesarenotavailable.
ProceduretoCheckRadiuswithCorrectGauge
Followthisproceduretocheckthefilletofthejournalafterthecrankshafthasbeenground.
1.Useadecimalradiusgaugewitharangeof2mmto20mm(0.095inchto0.75inch).Comparetheprofile
oftheradiusgaugewiththeprofileofthefillet.Iftheradiusgaugematchesthefillet,therewillbenospace
betweenthefilletandgauge.RefertoIllustration34.Aradiusgaugeinfractionscanbeusedafterthe
fractionsareaccuratelyconvertedtothedecimalormetricequivalents.
Radiusgaugesareavailablefromseveralcompanies,oneofthemislistedbelow.
Starrett
www.starrett.com
Phone(978)2493551
Fax(978)2498495
1.Putthecorrectsizeofradiusgaugeintothefillet.Theradiusgaugemustcomeintocontactwiththecenter
oftheradius.
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Illustration33
g01398955
Measuringtheradiusofthefillet
Illustration34
g01398957
Thegaugeisthecorrectsizebecausetheentiregaugeisincontactwiththeradiusofthefillet.
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Illustration35
g01398960
Theradiusistoolarge.Thenoseofthegaugeistheonlypartofthegaugethatcontactsthefillet.
Illustration36
g01398982
Theradiusistoosmall.Thegaugeiscontactingtheradiusattheshouldersofthegauge.
2.TheradiusofthecrankshaftmustmeetthespecificationsasfoundintheReuseandSalvageGuideline
specificationsfortherespectiveengineplatformtobereused.Refertothe"References"sectionfoundwithin
thisdocumentforalistofspecificationReuseandSalvageGuidelines.
Note:TheappropriateengineplatformReuseandSalvageGuidelinespecificationcontainsdimensionsofradii
beforethepeeningoperation.Refertothe"References"sectionfoundwithinthisdocumentforalistof
specificationReuseandSalvageGuidelines.Whenpossible,measurethefilletsbeforethepeeningoperation.
RefertoReuseandSalvageGuideline,SEBF8039,"CrankshaftVisualInspectionandMagneticParticle
Inspection"forcrankshaftinspectioninformation.
ProcedureforBracketCheckingtheRadiioftheJournalFillet
Thebracketcheckshouldbeusedwhentheexactgaugescannotbefound.Itwillbenecessarytomeasurethe
radiusofthefilletbyusingothergaugesthathavealargerradiusandsmallerradiusthanthespecifiedfillet.Refer
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tothefollowingexample.
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1.Useagaugethatissmallerthantheradiusofthefillet.Thenoseofthegaugeshouldcontactthecontourof
thefillet.RefertoIllustration35.Iftheshouldersofthegaugecontactthefillet,thenthegaugeislargerthan
thefillet.
2.Useagaugethatislargerthantheradiusofthefillet.Thenoseofthegaugeshouldnotcontactthecontour
ofthefillet.RefertoIllustration36.Ifthenoseofthegaugecontactsthefillet,thegaugeissmallerthanthe
fillet.
3.Thebracketcheckmethodshouldshowthattheradiusofthefilletisbetweenthegauges.Thecrankshaft
willgivenormalperformanceiftheselectedgaugesareclosetothespecifiedradiusofthefillet.The
crankshaftsmustalsomeettheotherphysicalrequirements.
SpecialCheckingProcedureforSpecificCrankshafts
Thefollowinginformationisusedtochecktheradiusoftherodandthemainfillet.Thisinformationisonlyused
for1W0400,0R5560,0R5474,AND0R5164crankshaft.
Illustration37
g01401227
Checkingtheradiusoftherod
(9)MaxPointofTangencywithSidewall
(10)TypicalProfile
TheprofileofthefilletmustfallwithinZones(A,B,andC).
TheminimumradiusinZone(C)is0.76mm(0.030inch).
TheminimumradiusinZone(B)is4.88mm(0.192inch).
TheminimumradiusinZone(A)is0.76mm(0.030inch).DoublefilletintersectionmayoccurinZone(A).Theintersectionmay
containasharppeak.Refertoitem(10).
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Illustration38
g01401286
Checkingtheradiusofthemainfillet
(9)MaxPointofTangencywithSidewall
(10)TypicalProfile
TheprofileofthefilletmustfallwithinZones(A,B,andC).
TheminimumradiusinZone(C)is0.76mm(0.030inch).
TheminimumradiusinZone(B)is2.34mm(0.092inch).
TheminimumradiusinZone(A)is0.76mm(0.030inch).DoublefilletintersectionmayoccurinZone(A).Theintersectionmay
containasharppeak.RefertotheTypicalProfile.
ProceduretoInspecttheJournal
ProceduretoChecktheHardnessoftheJournal
Note:Thehardnessofthejournalsshouldbecheckedbeforeanypolishingoperation.
Ifajournalshowssignsofhighheatorgrinding,checkthehardnessofjournal.ANonDestructiveTest(NDT)
methodsuchasusinganEquotiphardnesstestingtoolcanbeused.
Note:Donotuseasclerometersincethismethodmaydamagethecrankshaft.
Followtherecommendationsofthemanufacturerforuseofthehardnesstester.RefertoappropriateReuseand
SalvageGuidelinespecificationfortolerancesofhardness.Refertothe"References"sectionfoundwithinthis
documentforalistofspecificationReuseandSalvageGuidelines.Thehardnessreadingsmustbewithinthese
tolerances.
Note:Asoftspotmaybefoundonajournal.Checkbothsidesofthesoftareaifasoftareaisdiscovered.Ifthe
hardnessofthejournaliswithinthespecificationsonbothsidesofthesoftarea,thenthehardnessofthejournalis
acceptable.
NOTICE
OncrankshaftssuchastheSeries3208andSeries3300familiesof
engines,therearhalfoftherearmainjournalandtherearfilletcanbe
softerthanthespecificationsfoundinReuseandSalvageGuideline,
SEBF9220,"SpecificationsforCrankshaftsin3400,3300,3200,3100,
3000,andDseriesEngines".
ProceduretoCheckSurfaceFinish
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Illustration39
g01396169
Analyzingthesurfacefinish
Illustration40
g02714179
ThesurfacefinishofbearingjournalsshouldbecheckedwithapoweredSurfaceFinishAnalyzerthatwillstroke
thejournalautomatically.RefertoIllustration39.Theradiusofthestylusmustbeapproximately0.013mm
(0.0005inch)andtheunitshouldhavea0.80mm(0.0315inch)cutofflength.
Thetraveldirectionofthesurfacefinishmeasurementshouldbeparallelwiththedirectionofthegrindingmarks
(A),asshowninIllustration40.
Note:ThemaximumpermissiblesurfaceroughnessforbearingjournalsisfoundintheReuseandSalvage
Guidelinespecificationsfortherespectiveengineplatform.Refertothe"References"sectionfoundwithinthis
documentforalistofspecificationReuseandSalvageGuidelines.
Polishthejournalsifthesurfaceroughnessdoesnotmeetthespecifications.RefertoReuseandSalvage
Guideline,SEBF8042,"ProcedureforGrindingandPolishingtheCrankshaft".
Thesurfacefinishofthethrustfacemustbeatleast0.45mm(0.018inch).Ensurethatnowearstepsormarks
occurfromgrindingonthesurface.RefertoReuseandSalvageGuideline,SEBF8039,"CrankshaftVisual
InspectionandMagneticParticleInspection".
SurfaceFinishAnalyzers
Surfacefinishanalyzersareavailablefromseveralcompanies.
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TaylorHobsonLtd
POBox36
2NewStarRoad
Leicester,LE49JQ,England
www.taylorhobson.com
Phone44(0)1162763771
Fax44(0)1162460579
MahrFederalInc
1144EddyStreet
Providence,RI02905
USA
http://www.mahrfederal.com
Phone18003432050
Fax1(401)7843246
MitutoyoManufacturingCo.
965CorporateBlvd.
Aurora,IL60502
www.mitutoyo.com
Phone6308209666
Fax6308202614
Copyright19932016CaterpillarInc.
Todoslosderechosreservados.
RedprivadaparalicenciadosdelSIS.
WedOct19201618:49:15GMT0500(Horaest.Pacfico,Sudamrica)
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