797f Xq Off-highway Truck Wsp00001-up (machine) Powered By C175-20.pdf

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

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Welcome: r080crc15 Product: TRUCK Model: 797F TRUCK WSP Configuration: 797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine

Reuse And Salvage Guidelines Reuse and Salvage for Crankshafts {0674, 1202} Media Number -SEBF8042-44

Publication Date -25/09/2015

Caterpillar: Confidential Yellow

Date Updated -22/01/2019

i07642492

Reuse and Salvage for Crankshafts {0674, 1202} SMCS - 0674; 1202

Caterpillar Products All Cat Engines

Introduction Table 1 Revision

Summary of Changes in SEBF8042

44

C27 C32 updates

43

New Serial Number Prefixes Added

42

Added TIR specifications to C175 table.

41

Changed supporting text for surface texture.

40

Combined information from SEBF8039, SEBF8041, SEBF8043, SEBF8054, SEBF8102, SEBF8103, SEBF8269, SEBF9134, SEBF9184, SEBF9217, SEBF9220, SEBF9243, SEBF9401, added 31 part numbers and repaired 85 pixelated illustrations.

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow. This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Cat dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar. For technical questions when using this document, work with your Dealer Technical Communicator (TC). To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1

g02139237

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Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, then ensure that the procedure is safe for you and other people. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2

g00008666

This safety alert symbol means: Pay attention! Become alert! Your safety is involved. The message that appears under the safety alert symbol explains the hazard. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe. The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary Inspection of a crankshaft is necessary at rebuild to determine if the crankshaft can be used again, salvaged, or discarded. The visual inspection will determine if the crankshaft can be used again as-is or after reconditioning. This guideline provides the criteria for visual inspection and magnetic particle of crankshafts. If a crankshaft is within the inspection guidance that is shown in this guideline and the guidelines that are referenced, then the crankshaft can be expected to give normal performance until the next overhaul when the crankshaft is used again in the same application. If this guideline shows that a crankshaft cannot be used again, then do not use the crankshaft again. Correct any engine conditions that could have caused the need for reconditioning. This guideline provides the procedures necessary for salvage machining, grinding, polishing, and shot peening Cat crankshafts. Many crankshafts can be used again in the same application after being salvaged. The journals on a used crankshaft must be checked for size, roundness, straightness, wear on the thrust face, and the surface texture. If the crankshaft is ground undersize, then lobing, radius, straightness, and hardness of the journal must also be checked. This guideline gives the procedure for measuring and straightening of crankshafts. If a crankshaft meets the specifications found in this guideline, then the crankshaft can be expected perform normally until the next overhaul when the crankshaft is used again in the same application. Some bent crankshafts can be used again if the crankshaft is properly straightened. Measuring the crankshaft carefully is the first step in the salvage procedure. Note: Crankshafts from C9, C10, C11, C12, C13, and C15 series engines should not be straightened. If the crankshaft from any of these engines are bent more than the allowable specifications listed, then the crankshaft should be replaced. Note: Grinding a crankshaft is not always necessary. Most crankshafts can be returned to service after only a light polishing and cleaning. Crankshafts that have been reground for marine engines are approved by some marine certification societies and by some insurance companies. Contact the insurance company or a representative from the marine certification society for acceptability of crankshafts that have been reground. If the crankshaft is ground and polished according to this guideline, and meets the criteria of the inspection documents within the "Service Letters and Technical r080crc15 Information Bulletins" section of this publication, then the crankshaft can be expected to give normal performance until the next rebuild. Caterpillar: Confidential Yellow https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledpa… 2/139

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

Never install a crankshaft that fails specification references in this guideline. During reconditioning, correct any conditions that might have caused the original failure.

Service Letters and Technical Information Bulletins NOTICE The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References Table 2 References Media Number Channel1

Title "Why Reuse and Salvage Parts" https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z

SEHS8468

Special Instruction "Crankshaft Cleaning Procedure"

SEHS9031

Special Instructions , "Storage Procedure for Caterpillar Products"

SEHS9182

Special Instruction "Procedure for Handling, Cleaning, Assembly, Installation, and Protection of Service Replacement Crankshafts for 3600 Family Engines"

SMHS6959

Special Instruction "Installing Crankshaft Seals And Wear Sleeves Using The Former 9S-8868, 9S-8873, 9S-8881 And 9S-8888 Tools Groups"

Tooling and Equipment NOTICE Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Table 3 Required Tooling and Equipment Part Number

Description

0S-1616

1/4" - 20 X 1" Bolt

1A-4273

5/8" - 18 X 1 1/4" Bolt

1F-1160

Cold Chisel

1P-2321

Puller

1P-3075

Slide Hammer Puller

1U-5601

1/4" Drill Bit

1U-5608

25/64" Drill Bit

1P-5571

Nylon Bristle Brush 9.5 mm (⅜ inch)

1P-5572

Nylon Bristle Brush 19 mm (¾ inch)

1P-5573

Nylon Bristle Brush 31.8 mm (1 ¼ inch)

1P-7429

Nylon Bristle Brush 114.3 mm (4 ½ inch)

1P-9788

Nylon Bristle Brush 127.0 mm (5.0 inch)

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1U-7600

Slide Hammer Puller

2W-1733

Seal

2W-2288

Plug

3P-1568

Dial Indicator

3T-5447

Hydraulic Pump

4C-3377

1/4" Extractor

4C-4426

305 mm (12.0 inch) Extension

4C-5552

Nylon Bristles 57.2 mm (2 ¼ inch)

4C-6342

Nylon Bristle Brush 88.9 mm (3 ½ inch)

4C-6343

Nylon Bristle Brush 101.6 mm (4 inch)

4C-6344

Nylon Bristle Brush 139.7 mm (5 ½ inch)

4C-6345

Nylon Bristle Brush 152.4 mm (6 inch)

4C-6346

Nylon Bristle Brush 165.1 mm (6 ½ inch)

4C-6347

Nylon Bristle Brush 177.8 mm (7 inch)

4C-6348

Nylon Bristle Brush 190.5 mm (7 ½ inch)

4C-6349

Nylon Bristle Brush 203.2 mm (8 inch)

4C-6350

Nylon Bristle Brush 241.3 mm (9 ½ inch)

4C-6792

V.C.I Oil / Rust and Corrosion Preventative 18.93 L (5.00131 US gal)

4C-6794

V.C.I Oil / Rust and Corrosion Preventative 1.0 L (0.26420 US gal)

4W-6358

Bolt

4W-8089

Bolt

5P-0537

Washer

5P-4163

Indicator Contact Point

5P-8247

Washer

5P-8637

Crankshaft Support Group

6V-2010

Polishing Stone

6V-6000

Dial Indicator

6V-6035

Hardness Tester

6V-3182

Nylon Bristle Brush 7.9 mm (5/16 inch)

6V-3183

Nylon Bristle Brush 11.1 mm (7/16 inch)

6V-7067

Nylon Bristle Brush 6.4 mm (¼inch)

6V-7091

Nylon Bristle Brush 12.7 mm (½)

6V-7092

Nylon Bristle Brush 15.9 mm (⅝ inch)

6V-7093

Nylon Bristle Brush 25.4 mm (1.0 inch)

6V-7094

Nylon Bristle Brush 38.1 mm (1 ½ inch)

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6V-7095

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components Nylon Bristle Brush 44.5 mm (1 ¾ inch)

6V-7096

Nylon Bristle Brush 50.8 mm (2.0 inch)

6V-7926

Dial Indicator Group

7B-0337

Surface Plate

7E-4201

Bolt

7E-4725

Washer

7H-1940

Universal Attachment

7H-1941

Dial Indicator Base

7H-1948

Swivel Post

7H-3171

Plug

7N-2003

Dowel

8L-9802

Plug

8J-1600

Oil Filter

8J-8850

Oil Filter

8T-5096

Dial Indicator Test Group

9A-1593

Surface Texture Comparison Gauge

9F-2247

Plug

9S-9081

Sling

9U-7981

Ultrasonic Couplant 3.2 FL. oz (94 ml)

128-4845

Bolt Assembly

164-3310

Infrared Thermometer

168-7720 or 415-4055

Ultrasonic Wear Indicator Group Kit

168-7721 or 415-4051

Ultrasonic Wear Indicator

168-7722 or 415-4052

Ultrasonic Probe

222-3061

Air Drill

262-9727

Nylon Bristle Brush 12.7 mm (½)

266-2281

1/4 " Nylon Brush

303-9339

Lint Free Shop Towels

334-0519

Grease

383-8887

Dual Scale Feeler Gauge Set

386-3364

Straight Edge Ruler

448-3698

Profilometer Non-Bluetooth Feature

448-8941

Counterweight

473-8691

Outside Electronic Micrometer Set 2-6 inch

516-4613

1" X 72" U243 X 16 (P1200) Polishing Belt

516-4615

1" X 72" U245 X 16 (P2400) Polishing Belt

516-4616

55.5 mm X 1828.8 mm U243 X 16 (P1200) Polishing Belt

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516-4617

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

115 mm X 1828.8 mm U243 X 16 (P1200) Polishing Belt

516-4618

121.5 mm X 1828.8 mm U243 X 16 (P1200) Polishing Belt

516-4619

55.5 mm X 1828.8 mm U254 X 5 (P2400) Polishing Belt

516-4620

115 mm X 1828.8 mm U254 X 5 (P2400) Polishing Belt

516-4621

121.5 mm X 1828.8 mm U254 X 5 (P2400) Polishing Belt

FT0128

Driver

FT0129

Sleeve

FT0130

Driver

FT0131

Sleeve

FT0132

Driver

FT0133

Sleeve

-

Loctite® 620

Dealer Specific

Machine for Grinding Crankshafts, Grinding Wheels, and Accessories

Dealer Specific

Crankshaft Polisher

Dealer Specific

Machine for Balancing Crankshafts

Dealer Specific

Air Gauge

Dealer Specific

Equotip or Ultrasonic Hardness Tester

Dealer Specific

Oil Hole Cleaning Brush

Dealer Specific

Oil Hole Chamfer Salvage Tooling

Dealer Specific

Pneumatic machine for shot peening (1)

Dealer Specific

Test fixture for Almen strips

Dealer Specific

Standard test strips

Dealer Specific

Holders for test strips

Dealer Specific

Almen gauge in SAE Standard J442

(1)

Caterpillar prefers a pneumatic machine that is capable of producing consistent coverage with the intensity to meet Caterpillar requirements.

Crankshaft Nomenclature

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Illustration 3

g01443652

(1) Flange (2) Fillet (3) Web (4) Sidewall of the Journal (5) Connecting Rod Journal (6) Flange (7) Front Shaft (8) Main Journal (9) Oil Hole (10) Hub

Illustration 4

g01443858

(3) Web (4) Sidewall of the Journal (11) Machined Area of Sidewall (12) Flash-line (13) Trim Line for Flash-line

Illustration 5

g01444030

(6) Flange (14) Threaded Area

Illustration 6 (14) Threaded Area

g01444196

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(15) Keyway

General Information When a crankshaft is removed, installed, or moved, be careful not to damage the journals. Use nylon slings with a capacity greater than the weight of the crankshaft. Refer to Illustration 7.

Illustration 7

g01731938

Nylon straps

Put slings into position around two main journals or two rod journals that are equal distance from the ends of the crankshaft. Ensure that metallic objects do not come in contact with bearing journal surfaces, fillets, or other important machined areas. If a crankshaft is lifted by any other method, some type of protection such as thick rubber hose, plastic tubes, or soft brass must be put at the point of contact with the journals. These protective materials must be checked regularly for signs of wear and/or embedded metal particles.

Prior to Visual Inspection 1. Immediately after a crankshaft has been removed from an engine, look for any clear signs of heavy damage that cannot be corrected by reconditioning. 2. Clean the outside of the crankshaft with a high-pressure wash, steam, solvent, degreasing vapor, or a caustic cleaning and rinse. 3. Perform "Crankshaft Cleaning Procedure". 4. Perform "Crankshaft Visual Inspection".

Crankshaft Cleaning Procedure New or remanufactured crankshafts are covered in a rust preventative material. The crankshafts removed from engines are covered in engine oil, also a rust preventative. Before the crankshaft can be installed in an engine, the crankshaft must be cleaned according to the procedure given in this instruction. This cleaning procedure is necessary to remove all the rust preventative material and to clean all oil passages. After the cleaning procedure has been completed, install a plug in the hole at the side of each connecting rod journal. Do not perform any procedure, outlined in this publication or order any parts until you read and understand the information contained within.

General Information Note: For a new or remanufactured crankshaft, it is not necessary to remove the threaded plugs or core plugs that are at the side of the connecting rod journals. It is necessary to flush all oil passages according to the procedures in this instruction. If an original crankshaft is to be used again in an engine rebuild procedure, then the oil plugs must be replaced with new oil plugs. Remove and discard all the original oil plugs from the crankshaft and give the crankshaft and the oil passages a complete and thorough cleaning. Refer to the "Plug Removal" section within this document for further guidance removing oil plugs. Any debris from normal use such as carbon deposits or sludge not removed from the oil passages of a crankshaft will cause bearing failure. It is especially important to clean crankshafts that have been reground. No grinding debris such as metal chips and abrasive material can remain in the oil passages. Always use the procedure shown in this instruction to clean the crankshaft before it is installed in an engine. If the crankshaft is not to be inspected or installed immediately, then flush the oil passages with clean oil and put plastic plugs in all oil passage openings. Put a rust inhibitor over the complete crankshaft to prevent damage. The recommendation is to use VCI (Volatile Corrosion Inhibitor) storage bags if the storage period is to be for more than 30 days.

Brushes for Cleaning Procedure Good quality nylon brushes are necessary to perform the cleaning procedure.

NOTICE

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Do not use a brush that has worn or loose bristles. DO NOT use a https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledpa… 8/139

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components Do not use a brush that has worn or loose bristles. DO NOT use a brush that has metal bristles. Metal bristles that break off and are not removed can damage the bearings, crankshaft and/or other engine parts.

If Using Cat Nylon Bristle Brushes

Illustration 8

g06180533

(A) Nylon Brush (B) 4C-4426 Extension

If Cat nylon bristle brushes are used to clean a bores, a 305 mm (12.0 inch) 4C-4426 Extension (B) is required to attach the brushes to the extension. Select the appropriately sized brush, based on the bore size. 1. To use the 4C-4426 Extension (B), cut the twisted wire handle off nylon bristle brush (A) to the length needed to perform the task. 2. Slide the twisted wire handle into extension . 3. Use the two setscrews to hold the brush in place.

Flushing (Cleaning) Tools Crankshaft oil passages usually cannot be cleaned correctly or completely when only a high-pressure wash, or a high-pressure nozzle, is used to do the cleaning procedure. A nozzle that has an aerated (air assisted) liquid flow for cleaning is recommended. Use a 2 to 3 percent (by volume) alkaline cleaning solution (detergent) with the cleaning gun. Temperature of the cleaning solution must be 43° C to 66° C (110° F to 150° F). When connecting the cleaning gun, the recommendation is to install a pump capable of supplying the cleaning solution at 114 liter/min (30 gpm) and 860 kPa (125 psi). Adjust the cleaning gun pressure to 620 kPa (90 psi). Install a 20 micron filter for filtration of the cleaning solution. An 8J-8850 Oil Filter with an 8J-1600 Oil Filter can be installed as a filter for the cleaning solution. Note: To accomplish the cleaning procedure, first clean all oil passages thoroughly with the correct brush size. To remove debris (sludge, metal chips, etc.), use the cleaning gun with the cleaning solution to flush (wash out) each oil passage. Use a flashlight and/or bore scope to inspect each passage and make sure that the passages are all clean. If the cleaning procedure is not done completely and thoroughly, debris in the crankshaft oil passages can loosen and cause problems after the engine is rebuilt and put into operation.

Plug Removal Removal and Installation of Threaded Plugs Plugs must be removed, discarded, and replaced with new plugs. The oil passages must be thoroughly cleaned after visual inspection and any necessary reconditioning operations have been made. 1. If the oil plug is staked, then use a 10.0 mm (0.39 inch) drill to remove staked metal around the plug. Note: If a plug cannot be removed easily with the use of a 3/16 in Allen Wrench, then drill through the plug with a 6.0 mm (0.24 inch) drill and remove the plug with a 1/4" easy out remover. 2. After the oil passage has been cleaned, check the threads of the oil passage for damage. Clean up any nicked threads or those with burrs using the appropriate chaser tap. Inspect worn threads with an oversize no go plug gauge. Install with new plugs and tighten to the proper torque. Different crankshafts use different torques for the plugs. Refer to the specific specifications manual for your engine for the proper torque. Refer to "Crankshaft Cleaning Procedure" for the procedure to clean the oil passages. Some V-Engines with a 158.75 mm (6.250 inch) bore use a special self-locking bolt with a hexagonal socket head instead of the threaded plug. This bolt can be removed with a 3/8 in Allen Wrench. After the oil passage has been cleaned, install a self-locking bolt and tighten to the proper torque. Removal and Installation of Lightening Hole Plugs 1. Attempt to remove snap rings using snap ring pliers.

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Note: Some snap rings can be difficult to remove with pliers, if that is the case try alternative methods. Attempt to remove the snap ring with two screwdrivers, or cut the snap ring in half with a 1F-1160 Cold Chisel. Regardless of the method, be careful not to damage the snap ring groove or the bore. 2. Remove the plug with a 1P-3075 Slide Hammer Puller. Make a small hole a little off-center of the plug for easier removal. 3. Clean oil passages. 4. Install new core plugs. If the snap ring was twisted or cut during the removal process, install a new snap ring. Make sure that the new snap ring fits correctly in the snap ring groove. Refer to Table 4 for the correct drivers and sleeves that are needed for the installation of the plug and the snap ring. Note: Use 8L-9802 Plugs in V-Engines that have a 158.75 mm (6.250 inch) bore. Make sure that the plugs are installed. Table 4 Drivers and Sleeves for the Installation of the Core Plug Model

Driver

Sleeve

619C and 824 Tractor Engines D326, D337, D343, and D336 Engines

FT0128

FT0129

641, 650, 651, 657, 660, and 666 Tractor Engines

FT0130

FT0131

D353, D379, and D398 Engines in all applications

FT0132

FT0133

Crankshaft Cleaning Procedure

Sludge, metal chips, and/or other foreign material that is forced from the oil passages under pressure can cause personal injury if the proper protective measures are not used. Always wear protective clothing and eye protection when removing and installing crankshaft plugs, cleaning oil passages with a brush and electric drill, or when using the cleaning gun with the hot cleaning solution.

1. During any disassembly of the crankshaft, use plugs or covers to protect crankshaft oil passages. Use the correct lifting device for each crankshaft to avoid damage to the bearing journals and seal surfaces. 2. Remove as much external dirt and oil as possible before the final cleaning procedure. This cleaning will reduce the amount of contamination to the cleaning solution and the cleaning solution tank. Use steam cleaning or another similar procedure to remove external dirt and any rust preventive coating.

Illustration 9

g03711722

Cross section of a typical crankshaft (15) Crankshaft (16) Plug (17) Internal Oil Passage

Note: Step 3 is not necessary for a new or remanufactured crankshaft. 3. Remove all covers and plugs from the crankshaft oil passages. Refer to the section, "Plug Removal" within this guideline.

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Illustration 10

g01397329

Use the correct brush to clean the oil passages thoroughly.

4. Clean the Oil Passages It is important for the oil passages to be thoroughly cleaned. The oil holes must be cleaned from every possible angle to ensure that the oil holes are cleaned correctly. The oil holes must be cleaned from both the rod journal and the main journal ends. Also, the oil holes must be cleaned through the holes that lighten the crankshaft or the plug end of the oil holes. To make sure that oil passages are kept free of debris, flush all passages with solvent during the procedure to clean oil passages. After the oil passages are thoroughly cleaned, use an air hose to remove the remainder of the solvent.

NOTICE Do not operate the electric drill unless the end of the brush is in the oil passage. This step is especially important because crankshaft journals can be damaged by the metal end of the brush. Operate the electric drill at approximately 300 RPM.

a. Choose the correct size brush for the cleaning procedure. The diameter of the brush must be slightly larger than the diameter of the holes that are to be cleaned. Refer to Table 3 for brush specifications. b. Put the brush in a variable speed electric drill. Use a petroleum base cleaning solvent, with the brush and electric drill, to loosen any debris (sludge, carbon deposits, etc.) in the oil passages. c. Where possible, ensure that the end of the brush goes all the way to the end of each oil passage. Each oil passage must be cleaned from every possible direction. Clean all cross-drilled holes (holes that intersect) especially at hole ends. Clean these holes from both directions. d. When most of the debris has been removed using the brush and cleaning solvent, use a cleaning solution of detergent and water with the brush to remove all debris that can be seen. After all visible debris has been removed and flushed away, continue the cleaning procedure, especially in those areas that cannot be seen, or where it is difficult to see. Use a vigorous cleaning action with the brush while continuing to flush the passages with the cleaning gun and cleaning solution. e. Refer to Illustration 9, for those crankshafts (15) that use a threaded plug (16) in the hole at the side of each connecting rod journal, inspect the threads in these holes. If any of the threads are damaged or have burrs, use the correct size thread tap to clean or repair the threads. Again clean the plug hole and threads with the brush and cleaning solution. 5. Install New Oil Plugs Normally with new or remanufactured crankshafts, the plugs are sent in a package with each crankshaft. If necessary, refer to the Parts Identification Manual to verify the plug part number and quantity. If the threads in the crankshaft are oversized, then install the new plug with an even coating of Loctite 620 on the threads. Note: Do not use a plug if it is damaged or has burrs. Inspect each plug and remove all burrs before installation.

Illustration 11 Oil plug installed (18) "Staked" Oil Plug (19) Top of Oil Plug (20) Threaded Oil Plug

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a. Refer to Illustration 11, install the correct part number plug (20) in each hole at the side of a connecting rod journal. Top surface of each plug (19) must be a minimum of two threads below the bottom of the counter bore. b. Refer to the appropriate Disassembly and Assembly manual for assembly specifications. Tighten each plug to its correct installation torque. If the crankshaft has a 9F-2247 Plug or 7H-3171 Plug, then "stake" the crankshaft at one location at the side of each plug hole, refer to Illustration 11, location (18) to hold the plug-in position. To "stake" the crankshaft, use a center punch and hammer to move the metal from near the plug hole, so it goes over the top of the plug. Note: The 2W-2288 Plug is a self-locking plug so it is not necessary to do the "staking" procedure. It is necessary though, to ensure that the plug is tightened to the correct installation torque. c. If the crankshaft uses core plugs and snap rings in the lightening holes, then install the necessary core plugs and snap rings. Ensure that the snap ring is correctly seated in the snap ring groove. d. After the plugs have been installed, again flush all crankshaft oil passages with the detergent and water cleaning solution to wash out any metal particles caused during plug installation. e. Use clean water (no detergent) under pressure to flush the remainder of the cleaning solution from the oil passages, then use air pressure to dry the crankshaft. (Do not let the crankshaft surface dry by evaporation). Note: Put a coat of clean engine oil on the crankshaft and in the oil passages to prevent rust damage. f. If the crankshaft is not to be installed immediately, then flush the oil passages with clean oil and put plastic plugs in all oil passage openings. Put a rust inhibitor over the complete crankshaft to prevent damage. The recommendation is to use VCI (Volatile Corrosion Inhibitor) storage bags if the storage period is to be for more than 30 days. g. Before using a stored crankshaft, be sure to remove the rust inhibitor and all plastic plugs. Clean the crankshaft as necessary with the detergent and water solution to remove all evidence of the rust inhibitor. Be sure to flush the crankshaft with pressurized water, then dry and lubricate it as necessary before installation.

Crankshaft Visual Inspection After cleaning the crankshaft, the crankshaft must be inspected. The purpose of the crankshaft visual inspection is to determine quickly if the crankshaft can be reused as is, if the crankshaft will need any form of salvage machining, or if the crankshaft is damaged beyond repair. Salvage machining can include a polish only or an under size grind and polish procedure. The inspection process should have begun during the disassembly and cleaning stages. After the crankshaft has been cleaned, then inspect the crankshaft systematically beginning at the journals and move section by section toward the counterweights. The following procedures will provide guidance through the visual inspection process.

Crankshaft Bearings The crankshaft bearings reveal the health of the bottom end of an engine at time of disassembly. Assessment of the crankshaft bearings is a critical step in the crankshaft salvage process. This assessment is as important as inspection of the crankshaft. The bearings can reveal many underlying issues with the crankshaft in particular, but also with the engine as a whole and the conditions in which the engine operated. Having the physical main and rod bearings on hand throughout the crankshaft salvage process will help the decision-making process go smoothly with justification for the actions taken. If the physical bearings are impossible to retain, then a high-quality photograph of both the front and back of the bearings should be used. Proper bearing analysis can determine crankshaft straightness, journal profile, journal taper, prior rebuild quality, block, and connecting rod bore condition and operating conditions. Inspect the crankshaft bearings for any potential underlying engine issue. For further assistance on how to read and understand bearings refer to Reuse and Salvage Guidelines, SEBF8064, "Reuse and Salvage for Connecting Rods". The Reuse and Salvage Guideline, SEBF8064, is an excellent resource to explain the importance of a proper inspection, preventative measures, and the long-term benefits of a quality crankshaft regrind or polish.

Journal Surface Begin the visual inspection process of the crankshaft at the journals. Visually inspect every journal for any signs of damage or defect to determine the potential for reusability. Broken or Cracked Journals A journal that has any visible break or crack cannot be salvaged. The crankshaft must be discarded and replaced.

Illustration 12

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Typical example of a broken crankshaft or a cracked crankshaft

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Do not reuse.

Illustration 13

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Typical example of a broken crankshaft or a cracked crankshaft Do not reuse.

Illustration 14

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Typical example of a broken crankshaft or a cracked crankshaft Do not reuse.

Journals with Smearing Smearing is a form of adhesive wear. During adhesive wear, surfaces make physical contact and small high spots generate heat and micro weld themselves together. Because lubricant is often absent, heat continues to build until more general melting and adhesion smearing develops. When inspecting the crankshaft for smearing, the smearing observed is the transfer of bearing material micro welded onto the crankshaft. Journals with smearing can usually be used again after all smearing is removed. It is possible to polish out light smearing. However, it is more likely to require grinding to remove smearing. Due to the heat involved in the smearing process, it is recommended to check hardness after removal of smeared material. For procedures to check the hardness and dimensions of the journal.

Illustration 15 Typical example of smearing. Salvage processes can be attempted.

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Illustration 16

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Typical example of smearing Salvage processes can be attempted.

Journals with Heat Damage Heat damage often results from a lack of lubrication, a spun bearing, or excessive smearing. Smearing and adhesive wear are sometimes discolored to a blue/black shade as a result of heat. If little or no discoloration is present, this indicates that a significant supply of lube oil prevented extreme temperatures as adhesive wear progressed. Sufficient heat can be generated by adhesive wear to negatively alter the crankshafts heat treatment. When this happens, the crankshaft should not be ground undersized and reused. Heat damage can affect the hardness of the journal surface. Extra caution must be used if salvaging such a crankshaft. Only attempt to salvage heat damaged crankshafts if discoloration is minor, if the hardness of the journal is acceptable and if there is enough material on the journal to be reground to undersize specifications. The journal hardness must be checked after grinding. For procedures to check the hardness of the journal.

Illustration 17

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Journal that shows moderate signs of heat and smeared material Salvage grinding processes can be attempted.

Illustration 18

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Journals that show signs of significant heat and significant bluing. Salvage grinding processes shouldNOTbe attempted.

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Illustration 19

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Journals that show signs of heat and smeared material Salvage grinding processes can be attempted.

Journals with Dents or Scratches Circumferential scratching of journal surfaces is a sign of abrasive wear. Since journals are heat treated to high hardness levels, abrasive scratching is usually caused by even harder particles such as sand, grit blast, or sanding disc particles. Small, fine abrasive particles have a tendency to polish the journal surface while larger, course particles cut and gouge the surface. Steel, cast iron, and aluminum chips are softer and seldom scratch the surface. The following crankshafts can be used again after the journals are salvaged and only if the profiles and the finishes of the journal surfaces are acceptable. For the measurement of the profile and the surface texture. Crankshafts that have a deep scratch on a rod journal or on a main bearing journal might be salvageable. The depth and the location of the scratch on the crankshaft are the main considerations when making a salvage decision.

Illustration 20

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Example of lightly scratched bearing journals Salvage grinding processes can be attempted.

Illustration 21

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Example of lightly scratched bearing journals Salvage grinding processes can be attempted.

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Illustration 22

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Example of lightly scratched bearing journals Salvage grinding processes can be attempted.

Illustration 23

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The journal has a single heavy scratch on the circumference. Salvage grinding processes can be attempted.

A journal that has a deep scratch going around the circumference might be salvaged. Depending on how deep the scratch is, a regrind might be possible. After grinding, the journal must meet the surface profile and dimensions.

Illustration 24

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Small dent on rod journal Salvage grinding processes can be attempted.

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Illustration 25

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Deep scratch on rod bearing journal Salvage grinding processes can be attempted.

Illustrations 24 and 25 show dents and scratches on a rod journal. Due to the torsional loading on a rod journal, do not reuse a crankshaft that has a small dent or scratch on a rod journal which cannot be removed by grinding undersize. Depending on how deep the dent or scratch is, a regrind might be possible. After grinding, the journal must meet the surface profile, surface texture, magnetic particle inspection, and dimensions. Main journals have a constant rotational load it may be possible to salvage main journals by polishing off the high spots of the small dent or scratch. Use the crankshaft again only if the dent or the scratch is shorter than half the width of the journal, the dent, or the scratch does not go beyond the width of the bearing and the dent or the scratch does not go into a fillet. Refer to Illustration 25 as an example of a scratched journal that meets these requirements. Remove any burrs with a 6V-2010 Polishing Stone and then polish the journal. After polishing, inspect the journal for surface texture and magnetic particle inspection. If the journal is not acceptable, then a regrind might be possible. After regrinding, the journal must meet the surface profile, surface texture, magnetic particle inspection, and dimensions.

NOTICE The polishing stone is only to remove the burrs or any raised edges. Do not use the 6V-2010 Polishing Stone to remove the entire defect.

Wear Steps on Journals Wear steps can form on the journal surface from normal wear or from debris embedded in the bearing. If the wear step can be felt and has a sharp edge, it is likely from debris harder than the surface of the journal. This type of wear step should be treated like a scratch. If a wear step can be felt on the surface of the connecting rod journal, do not reuse, but salvage processes may be attempted. Wear steps that are worn into the crankshaft from normal operation usually cannot be felt easily. These are areas where the bearing micro-polishes the crankshaft. In these instances, do not regrind the crankshaft for only a visible wear step. Use the crankshaft again without regrinding if the wear step maximum height of 0.018 mm (0.0007 inch) and the maximum width of 0.89 mm (0.035 inch) is not exceeded.

Illustration 26

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Wear steps on the journal surface This particular journal has other damage, for this example focus only on the wear steps. Wear steps polished in the middle of the journal around the bearing oil passage. Inspect the journal surface for finish and diameters.

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Illustration 27

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Acceptable step on a connecting rod journal

On some crankshafts, a wear step might become visible on double rod journals, refer to Illustration 27. In the situation of double rod journals, if the crankshaft journals do not need salvage techniques for any other reason, then do not regrind the journal for only the visible wear step. If the journals are damaged to the point of needing a regrind, then it is acceptable to grind the rod journals with the double plunge method. Refer to section "Double Plunge Grinding" for information on the double plunge method of grinding.

Illustration 28

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Wear step on the journal surface Salvage processes may be attempted.

In Illustration 28, crankshaft journals with wear steps that can be seen, felt, or that measure more than 0.5 mm (0.02 inch) must be ground to an acceptable profile. Water Damaged Journals Unprotected crankshafts are susceptible to water damage through direct contact or humid environments. If water contacts the crankshaft, the metal begins to corrode. During the corrosion process pitting occurs and can destroy the critical surface texture of the crankshaft journals. If heavy corrosion is present on the surface of the journals, then the oil passages must be inspected with a bore scope. If corrosion is found within the oil passages, it is not recommended to salvage the crankshaft. If light corrosion is found on the journal surfaces and the oil passages are clear, then salvage processes can be attempted.

Illustration 29

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Typical example of corrosion. The corrosion has destroyed the hardened surface of the crankshaft. Salvage grinding processes shouldNOTbe attempted.

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Illustration 30

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Typical example of corrosion. The corrosion has pitted the hardened surface of the journals heavily. Salvage grinding processes shouldNOTbe attempted.

Illustration 31

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Visual damage from water on the journal surface. Salvage processes can be attempted .Reuse a crankshaft that has damage from water only after the journal is polished and measured.

Illustration 32

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Visual damage from water on the journal surface. Salvage processes can be attempted. Reuse a crankshaft that has damage from water only after the journal is polished and measured.

Journals Damaged During Machining Careful salvaging of Cat crankshafts is critical for long-term durability. Sometimes damage may happen during the salvage machining process. Damage due to grinder heat or damage in critical areas such as in a fillet area or on the journal surface must be inspected carefully to ensure the durability of the crankshaft.

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Illustration 33

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Normal number of depressions on the bearing journal surface and a normal number of depressions in the fillet

Do not reuse the crankshaft if there is a high concentration of depressions on the surface of the bearing journal. Reuse the crankshaft if there is few depressions on the surface of the bearing journal.

Illustration 34

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Signs of chatter on bearing journal surface Salvage processes may be attempted.

Chatter is caused from the grinding wheel skipping on the surface of the journal. The journal must be reground. Chatter can be identified by horizontal, parallel lines on the journal surface. Reuse the crankshaft after the journal has been ground, polished, inspected and the chatter can no longer be seen.

Illustration 35

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Improper finish of the journal Salvage processes can be attempted.

Do not reuse a crankshaft if the journal does not have the proper finish. If the surface texture is not within specifications, then the journal surface must be ground to the next undersize journal diameter. The finish must be suitable and complete around the circumference of the journal.

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Illustration 36

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Embedded metal particles and burrs on the surface of the bearing journal Salvage processes can be attempted.

Do not reuse a crankshaft if there are embedded metal particles and burrs on the surface of the bearing journal. The journal with embedded particles must be ground under size.

Oil Hole Crankshafts with sharp edges at the oil holes can be used again after the sharp edges are removed and the oil holes are polished. Oil holes with debris in the oil hole must be thoroughly flushed of all debris. Refer to "Crankshaft Cleaning Procedure".

Illustration 37

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Oil hole with sharp edges.

Illustration 38

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Oil hole with sharp edges

Do not reuse a crankshaft if the oil holes have sharp edges.

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Illustration 39

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Debris in oil hole

Do not reuse a crankshaft if there is debris in the oil hole. Clean and inspect all oil holes.

Fillet Inspect the fillet area after the journals. Visually inspect every fillet for any signs of damage or defect to determine the potential for reusability. The fillet area is a stress riser for the crankshaft and is considered a high risk area. Extra precaution must be made when making a reuse or salvage determination when visually inspecting the fillet area.

Illustration 40

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Signs of bearing material in the fillet Salvage processes may be attempted.

You may reuse a crankshaft if bearing material can be removed from the fillet by polishing.

Illustration 41

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Scalloped fillet on the main journal

You may reuse a crankshaft if a main journal has been scalloped. Scalloping looks like beach or lap marks. Usually scalloping is caused by chatter from the grinding wheel. r080crc15 Caterpillar: Confidential Yellow

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Illustration 42

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Scalloped fillet on the rod journal Salvage processes may be attempted.

Do not reuse a crankshaft if a connecting rod journal has been scalloped. If there is enough material, it may be possible to grind the scalloping off the rod journal.

Illustration 43

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Pitting on a fillet Salvage processes may be attempted.

Do not reuse a crankshaft if pitting is present on a fillet. Use caution in making this reuse decision, the danger is in how deep the corrosion has penetrated the fillet area. If all pitting can be removed by grinding or polishing, then the crankshaft may be salvaged. If pitting remains after grinding, then the crankshaft cannot be reused.

Illustration 44

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Pitting on a fillet Salvage processes may be attempted.

Do not reuse a crankshaft if pitting is present on a fillet. Use caution in making this reuse decision, the danger is in how deep the corrosion has penetrated the fillet area. If all pitting can be removed by grinding or polishing, then the crankshaft may be salvaged. If pitting remains after grinding, then the crankshaft cannot be reused.

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Illustration 45

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A journal that has been reground

After a journal has been reground, there may be a change in the contour of the lower part of the fillet. There may also be a change in the shape in the lower part of the fillet. Reuse the crankshaft if the point of change in the contour of the fillet is above the point that is shown in Illustration 46. Make sure that the fillet blends smoothly with the journal surface.

Illustration 46

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Illustration 47

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Fillets without a proper finish Salvage processes may be attempted.

Fillets without a proper finish must be ground to an acceptable finish according to the appropriate Crankshaft Specification Reuse and Salvage Guidelines.

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Illustration 48

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Fillets without a proper finish Salvage processes may be attempted.

Fillets without a proper finish must be ground to an acceptable finish.

Illustration 49

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Fillet with marks from heat Salvage processes may be attempted.

You may reuse the crankshaft only if the hardness of the journal is acceptable.

Sidewall

Illustration 50

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Wear step on the sidewall

Use the crankshaft again if the wear step is less than 0.12 mm (0.0047 inch) before grinding and the sidewall is smooth after grinding.

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Illustration 51

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Damage to the sidewall Salvage processes may be attempted.

You may reuse the crankshaft after the raised material is removed and the sidewall is smooth.

Illustration 52

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Oil and carbon deposits on sidewall Salvage processes may be attempted.

You may reuse the crankshaft after the sidewall is polished and the deposits are removed. If polishing will not remove carbon deposits, then do not reuse the crankshaft.

Illustration 53

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Scratch on sidewall Salvage processes may be attempted.

You may reuse the crankshaft after the burrs are removed with the 6V-2010 Polishing Stone, and the sidewall is polished. Use the following crankshafts after thorough inspection according to the section "Crankshaft Magnetic Particle Inspection for Cracks".

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Illustration 54

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Burns from grinding Do not reuse a crankshaft that has burns from grinding.

Illustration 55

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Burns from grinding Do not reuse a crankshaft that has burns from grinding.

Illustration 56

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Burns from grinding Do not reuse a crankshaft that has burns from grinding.

Discoloration from grinding is caused by heat buildup generated during the grinding process. This excessive heat can damage the hardened surfaces of the crankshaft. The damage to the hardened surfaces can lead to a shortened crankshaft life, even if the discoloration is removed. It is recommended not to reuse that any crankshaft that has any heat-related damage.

Thrust Face Thrust Face Wear Step

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Illustration 57

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Wear step on the thrust surface

You may reuse the crankshaft if the wear step is outside the surface of the thrust bearing and the dimensions are acceptable. If the wear step is in the surface of the thrust bearing, then the wear step must be ground out of the surface of the thrust bearing. The dimensions must be acceptable after the step is ground. Thrust Face Burr On Certain machine C27/C32 engines the connecting rod may create a sharp burr on the thrust face of the crankshaft. The burr is commonly accompanied with radial scoring on the sidewall of the crankshaft and connecting rod. If a sharp burr is found on the crankshaft, ensure that the mating connecting rod is inspected for any damage.

Illustration 58

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Area between arrows is where side wall burr damage will occur.

Thrust Face Corrosion

Illustration 59

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Corrosion on thrust surface

You may reuse the crankshaft after the thrust face is polished and all corrosion is removed. Thrust Face Smearing

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Illustration 60

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Smearing on thrust face

You may reuse a crankshaft after the thrust face is polished and all bearing material is removed. Thrust Face Wear Step

Illustration 61

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Wear steps on the thrust surface

The thrust face of the crankshaft is damaged in Illustration 61. Use the crankshaft only if the wear step can be ground clean without grinder burns and the dimensions of the thrust face meet the specifications. Thrust Face Grinding Wheel Damage

Illustration 62

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Damage from grinding wheel on thrust face Do not reuse the crankshaft if the thrust surface has been damaged by the grinding wheel.

Thrust Face Grinder Burn

Illustration 63

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Grinder burns on the thrust surface Do not reuse the crankshaft

Counterweight Inspection Crankshaft counterweights are critical for balance and durability of the crankshaft. Some Cat crankshafts utilize a counterweight forged with the crankshaft, others utilized a bolt on counterweight. Counterweights need visual inspection for damage. Sometimes, the joints between bolt on counterweights and crankshaft counterweight mounting pads require careful inspection. Forged Counterweight Visual Inspection Do not reuse a crankshaft with forged counterweights if there is excessive material or damage to the counterweight.

Illustration 64

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Damage to forged counterweight Do Not Use

Bolt on Counterweight Inspection If a bolt on counterweight is removed for any reason, then both surfaces of the joint must be inspected for fretting and other signs of damage. If fretting is excessive on the counterweight pad area, then either the counterweight or the entire crankshaft assembly must be replaced. If the damaged counterweight is not serviceable, cannot be replaced, or the crankshaft cannot be rebalanced, then the crankshaft assembly must be replaced. Note: It is recommended that the rear counterweight from crankshafts in machine engines be removed and inspect both surfaces of the joint.

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Illustration 65

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Graphical representation of counterweight fretting. (21) Counterweight (22) Counterweight Bolt Hole (23) Fretting

Counterweight pads are precisely machined with slight concavity and cannot be salvage machined. Due to the concave machining of the counterweight, fretting is normally seen at the outside edge of the counterweight and crankshaft pads. The extent of fretting on the counterweight, and the location of the fretting, must be taken into account when making a reuse decision. Refer to Illustration 65 for a visual reference of fretting. Fretting on either surface anywhere except the outside edges is not normal. In general fretting is acceptable for reuse if the following are true: Fretting is outward of the center line of the outer counterweight bolt bore. Fretting that is not within 2 mm (0.08 inch) of the counterweight bolt bore. The original machining marks are mostly still visible through the fretting.

Illustration 66

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Counterweight inspection. Original machine marks are visible. Fretting is not present at the rim of the bolt hole. Fretting does not extend inward of the center line of the bolt hole. Reuse (A) 2 mm (0.08 inch) damage free zone surrounding bolt hole.

Illustration 67

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Counterweight inspection. Original machine marks are mostly visible. Fretting is not extensive, not present at the bolt hole and does not extend inward of the center line of the bolt hole. Reuse (A) 2 mm (0.08 inch) damage free zone surrounding bolt hole.

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Illustration 68

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Counterweight inspection. Original machine marks are not visible and fretting is extensive (top arrow). Fretting is present within 2 mm (0.08 inch) of the bolt hole and extends inward of the center line of the bolt hole. Do Not Reuse

Illustration 69

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Counterweight inspection. Original machine marks are not visible and fretting is extensive. Fretting is within 2 mm (0.08 inch) of the bolt hole, extends past the center line of the bolt hole and into the inboard side of the counterweight. Distinctive fretting pits can be seen at the edge of the bolt hole. Do Not Reuse

Crankshaft Counterweight Mounting Pad Inspection Mounting pads with minor fretting outward of the center line of the outer bolt holes can be used again. The mounting pad may also be resurfaced slightly to remove pitting and to restore proper flatness. Burrs or raised material can be removed from the mounting pad by using a 30 mm (1.2 inch) wide file. First, remove the dowel. Then use light pressure and remove only the material which prevents the counterweight from making complete contact with the mounting pad.

Illustration 70

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Counterweight Mounting Pad Inspection Minor fretting toward the outside edge of the pad. Fretting is outward of the outer bolt hole center lines. Original machining marks are clearly visible through the fretting. Reuse (A) 2 mm (0.08 inch) damage free zone surrounding bolt hole.

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Illustration 71

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Counterweight Mounting Pad Inspection Minor fretting outward of center line of the outside bolt holes. No fretting present at the edge of the bolt hole. Original machining marks are clearly visible through the fretting. Reuse

Illustration 72

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Counterweight Mounting Pad Inspection Heavy fretting on mounting pad, worn through the machining marks. Fretting extends inward of center line of bolt hole. Do Not Reuse Salvage Machine Mounting Pad if Possible

Illustration 73

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Counterweight Mounting Pad Inspection Heavy fretting and pitting on mounting pad, worn through the machining marks. Fretting is beyond center line of bolt hole and distinct at the edge of the bolt hole. Do Not Reuse Salvage Machine Mounting Pad if Possible

Holes for Lightening the Crankshaft

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Illustration 74

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Fine crack in lightening hole

Do not reuse a crankshaft if there are any cracks in the holes for lightening.

Keyway

Illustration 75

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Keyway of the crankshaft

You may reuse a crankshaft after the rough edges of the keyway have been removed with a file.

Tapered Shaft

Illustration 76

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Tapered shaft on the crankshaft

Use the crankshaft again after the burrs are removed with a 6V-2010 Polishing Stone.

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Illustration 77

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Crankshaft gears with broken teeth or pitted teeth

Do not reuse crankshafts with gears that have broken or pitted teeth.

Illustration 78

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Crankshaft gears with broken teeth or pitted teeth

Do not reuse crankshafts with gears that have broken or pitted teeth.

Seal Surface Damaged seal surfaces can be reconditioned by installing a wear sleeve over the groove. Damaged seal surfaces can also be reconditioned by installing the seal to one side of the wear. For wear sleeve installation, refer to the Special Instructions listed below for the process and refer to the Catalog listed below for the correct tooling. Refer to Special Instruction, SMHS6959, "Installing Wear Sleeves and Crankshaft Seals Using The Former 9S-8868, 9S-8873, 9S-8881, and 9S-8888 Tools Groups" for more information.

Illustration 79

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Groove on seal surface

Do not reuse a crankshaft if a groove is present on the circumference of the seal surface.

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Illustration 80

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Groove on seal surface

Do not reuse a crankshaft if a groove is present on the circumference of the seal surface.

Illustration 81

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Surface of oil slinger

The surface of the oil slinger on engines with a 158.75 mm (6.250 inch) bore must be free of scratches, burrs, or grooves.

Thread Inspection and Salvage Inspect the flywheel and damper threads for damage. If the threads are damaged to the point of needing replacement, then it is acceptable to utilize the appropriate HeliCoil standard insert. When utilizing a Heli-Coil insert, it is recommended that adjacent holes should not be reworked and do not repair more than half the holes on either the flywheel or the damper end.

Following Visual Inspection Specific instructions for the following steps are found in "Crankshaft Cleaning Procedure" in this guideline. 1. All threaded oil plugs must be removed and the oil passages cleaned thoroughly. 2. All the plugs from the core of the hole that lightens the crankshaft must be removed and the oil passages cleaned thoroughly. Discard used oil plugs and replace with new after salvage process is complete. 3. The crankshaft must be prepared for storage.

Crankshaft Magnetic Particle Inspection for Cracks Summary This guideline provides the process for crankshaft magnetic particle inspection and the types of indications that could be detected. This guideline provides the acceptance criteria for cracks that may have been introduced during the service life or during the reconditioning of the crankshaft. Crankshafts that meet the requirements in this guideline and in the specifications guidelines can be expected to give normal performance. Note: Crankshafts that meet the Caterpillar criteria may not meet the criteria of marine certification societies. Examples of marine certification societies are American Bureau of Shipping, Bureau Veritas, Korean Register of Shipping, Class NK, and RINA.

Glossary of Terms

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Axial Indication - An indication traveling along the longest dimension of the component. Refer to the Section: "Circumferential and Axial Indications".

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Circumferential Indication - An indication traveling around the circumference of the component. Refer to the Section: "Circumferential and Axial Indications". Coil Shot - Longitudinally magnetizing the test part by placing the crankshaft inside a magnetizing coil and passing electrical current through the coil. This technique creates induced magnetization. The electrical current is only in the coil and the magnetic field around the coil is induced into the component. Refer to the Section: "Magnetic Particle Techniques". Continuous Magnetism Method - Magnetizing the test part immediately after or during application of the carrier solution. Closed Indication - An indication that cannot be seen or felt after the particles have been removed. Refer to the Section: "Closed Indications". Crack - A fracture in the steel. This type of discontinuity can be highly detrimental to the crankshaft. Refer to the Section: "Cracks". Chicken Wire - A network of indications, normally only seen on unmachined, forged surfaces. Usually the result of excessive copper and heating. Direct Magnetization - Circularly magnetizing the test part by securing the crankshaft between the head stocks and passing current through the crankshaft. Also referred to as “head shot” as electricity passes directly through the component. Refer to the Section "Magnetic Particle Techniques". Discontinuity - An interruption in the physical structure or configuration of a material or component. A discontinuity can be either a surface or subsurface discontinuity. (Examples: cracks, forging laps, machining tears). Refer to the Section: "Important Areas of Inspection". False Indication - Any collection of particles not held by a magnetic field and not caused by a material discontinuity. (Examples: fingerprints, smudges, drips). Refer to the Section: "Indication Examples". Flash-line - An area along the length of a forging where the forging dies meet, often exhibiting concentrations of nonmetallic inclusions because of material flow during forging. This area is also referred to as the “parting line” or “trim line”. Forging Lap - A surface defect appearing as a fold in the steel. Forging laps occur during the forging of the crankshaft. Also referred to as "laps". Grain Flow - The elongation of the crystalline structure of the steel. The grain flow is shaped by the forging dies. Grain flow is sometimes seen on magnetic particle inspection if the magnetizing amperage is too high. Grinder Burn - A microstructural change in the material due to overheating at during grinding. Grinder Cracks - Small cracks on a ground surface caused by overheating during grinding. Some grinder cracks are small and are rarely detectable by the unaided eye. Head Shot - Circularly magnetizing the test part by securing the crankshaft between the head stocks and passing current through the crankshaft. Also referred to as “direct magnetization” as electricity passes directly through the component. Refer to the Section "Magnetic Particle Techniques". Indication - A collection of magnetic particles held in position by magnetic force. An indication can be relevant, non-relevant, or false. Refer to the section: "Indication Examples". Imbedded Scale - Iron oxide, which flakes off during the forging operation and adheres to the forging dies. This scale will be imbedded into the crankshaft surface and will sometimes come out during machining, leaving a pit in the machined surface. If the scale does not come out during machining, then the scale will be clearly visible. Lap - A surface defect appearing as a fold in the steel. Laps occur during the forging of the crankshaft. Also referred to as "forging laps". Linear Indications - An indication with length equal to, or greater than, three times the width. Refer to the Section: "Linear and Rounded Indications". Longitudinal - Parallel to the crankshaft. Manganese Sulfide Inclusion - A nonmetallic inclusion. Manganese sulfide inclusions are non-crystalline, relatively soft, elongated inclusions that usually do not affect the integrity of the crankshaft. Manganese sulfide inclusions are often seen at the flash-line as manganese and sulfur are added to the steel for improved machinability. Refer to the Section: "Non-Metallic Inclusions". Nonmetallic Inclusion - Chemical compounds and nonmetal material that is present in the steel. Non-relevant Indication - An indication held by a magnetic field not due to a discontinuity (Examples: edges, corners, threads, machining marks). Refer to the Section: "Indication Examples". Open Indication - An indication that can be seen or felt after the magnetic particles have been removed. Refer to the Section: "Open Indications". Oxide Inclusion - A non-metallic inclusion that is hard, brittle, and angular. Oxide inclusions may be located away from the flash-line. Parting Line - An area along the length of a forging where the forging dies meet, often exhibiting concentrations of nonmetallic inclusions because of material flow during forging. This area is also referred to as the “flash line” or “trim line”. Ultraviolet Light - Light that has a higher frequency than white light. UV light is used to detect fluorescent magnetic particle indications. Relevant Indication - An indication held by a magnetic field due to a discontinuity. Relevant indications can be open or closed, linear, or rounded, surface, or subsurface and circumferential or axial. Residual Magnetism Method - Magnetizing the part before applying the carrier solution, relying upon the residual magnetism in the test part to attract particles. Refer to the Section: "Magnetic Particle Techniques". Rounded Indications - An indication with a length less than three times the width. Refer to the Section: "Linear and Rounded Indications". Scratch - A scratch is a form of an open indication. Scratches can look like cracks and must be checked with a magnifying glass. Upon inspection scratches are typically shiny at the bottom of the groove. Refer to Illustration 143. Seam - Usually a long straight defect, found in most instances on the unmachined surface of the crankshaft. These are typically elongated laps or cracks in the original ingot or bar material. Service Crack - A sharp discontinuity, individual or grouped, generally occurring on bearing or gear surfaces. Stringer - Nonmetallic inclusions in material that has been elongated in the forging process.

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Steady Rest Tear - A series of small cracks due to excess friction between the steady rest of the grinder and the crank journal. Trim Line - An area along the length of a forging where the forging dies meet, often exhibiting concentrations of nonmetallic inclusions because of material flow during forging. This area is also referred to as the “parting line” or “flash line”.

Indications An indication is any collection of magnetic particles held in position by magnetic force that can indicate a discontinuity. There are three basic types of indications: relevant indications, non-relevant indications, and false indications. Proper classification of the type of indication discovered is important. There are descriptive terms in use with indications. These terms include: linear indications, rounded indications, circumferential indications, axial indications, surface discontinuities, and subsurface discontinuities. Indication Examples

Illustration 82

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(1) Non-Relevant Indications - created by magnetism at corners and edges. (2) Relevant Indication - created by this crack. (3) False Indication - Fingerprints and smudges are not held by magnetism.

False Indications False indications can be caused by any of the following: dirt, fingerprints, smudges, rust, an improper mixture of the carrier solution, and/or using too much current. A second inspection must be made after a false indication is found. Thoroughly clean the area prior to the second inspection. False indications do not return. Refer to Illustration 82 for an example of a false indication. Relevant Indications An indication held by a magnetic field due to a discontinuity. Relevant indications can be open or closed, linear, or rounded, surface, or subsurface and circumferential or axial. Open Indications Note: An open indication is an indication that can be seen or felt after the magnetic particles have been removed. Open indications are caused by inclusions, pitting, large cracks, or heavy scratches. If an open indication cannot be ground out or is found in a critical area, then the crankshaft cannot be reused. Refer to the section "Magnetic Particle Inspection" for further guidance.

Illustration 83

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An example of an open indication with the carrier solution under an ultraviolet light

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Illustration 84

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

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Illustration 83 without the carrier solution shown under white light.

Illustration 85

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An example of an open indication with the carrier solution under an ultraviolet light

Illustration 86

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Illustration 85 without the carrier solution shown under white light.

Note: Scratches can look like open indications under magnetic inspection. Scratches can be checked with a magnifying glass and are shiny at the bottom of the groove. Refer to the section "Magnetic Particle Inspection" for further guidance. Closed Indications Note: An indication that cannot be seen or felt after the magnetic particles have been removed. A closed indication is not necessarily a subsurface discontinuity nor does a closed indication imply acceptability. Often cracks, the most serious type of defect, are closed indications.

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Illustration 87

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An example of a closed indication with the carrier solution under an ultraviolet light.

Illustration 88

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Illustration 87 without the carrier solution shown under white light.

Illustration 89

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An example of a closed indication with the carrier solution under an ultraviolet light.

Illustration 90

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Illustration 90 without the carrier solution shown under white light.

Cracks Note: Cracks have rougher edges than other types of indications. Cracks are normally continuous. Some small cracks on journals might be able to be ground out. Cracks in any other area of the crankshaft are not permitted. r080crc15 Caterpillar: Confidential Yellow

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Illustration 91

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An example of a crack with the carrier solution under an ultraviolet light

Illustration 92

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Illustration 91 without the carrier solution shown under white light.

Illustration 93

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Nonrelevant flash line indication due to trim line edge under ultraviolet light

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Illustration 94

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Image 93 as seen under white light.

Some sharp linear indications may appear to be cracks but after further investigations are discovered not to be an actual crack. Sharp transitions near the flash-line can create non-relevant indications. Refer to Illustrations 93 and 94. Linear and Rounded Indications Note: An indication with a length equal to, or greater than three times the width is considered linear. This length to width ratio is constant regardless the shape of the indication.

Illustration 95

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Examples of linear indications.

Note: An indication with a length less than three times the width is considered rounded. This length to width ratio is constant regardless the shape of the indication.

Illustration 96

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Examples of rounded indications.

Circumferential and Axial Indications Indications can appear to travel along the axis or around the circumference of a component. Indications that travel along the axis is considered to be an axial indication. Indications that travel around the circumference of the component is considered to be circumferential.

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Illustration 97

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(4) Circumferential Indication (5) Axial Indication

Forging Indications Some abnormalities created in the forging process may have met the original manufacturing criteria for crankshafts. These indications will sometimes be discovered during reuse inspection. These indications will include forging laps, seams, flash line, imbedded scale, and chicken wire.

Discontinuities A discontinuity is any interruption in the normal physical structure of the steel. There are two general types of discontinuities: surface and subsurface discontinuities. Most relevant indications will be a type of discontinuity. Note: A surface discontinuity extends to the surface of the crankshaft. Indications from surface discontinuities are typically bright, fine, and distinct.

Illustration 98

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An example of a surface discontinuity with the carrier solution under an ultraviolet light.

Note: Indications from subsurface discontinuities are typically broad, faint, and “fuzzy”. A subsurface discontinuity is wholly below the inspected surface.

Illustration 99

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An example of a subsurface discontinuity with the carrier solution under an ultraviolet light.

Machining Discontinuities After forging, the crankshaft must be machined. A result of machining process may cause various discontinuities. These discontinuities will include scratches, steady rest tears, grinder burn, and grinder cracks.

Non-Metallic Inclusions Non-metallic inclusions are a form of discontinuity and are a result of segregated alloys in the steel. The inclusions are composed of chemical compounds and nonmetal material that is present in the steel. There are two likely types of non-metallic inclusions: manganese sulfide inclusions and oxide inclusions. Note: An inclusion that has been elongated due to the forging process is often referred to as a stringer. Manganese Sulfide Inclusions Manganese sulfide inclusions are non-crystalline, soft, elongated inclusions that usually do not affect the integrity of the crankshaft.

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Illustration 100

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Example of a manganese sulfide inclusion

Oxide Inclusions Oxide inclusions are of greater concern than manganese sulfide inclusions because oxides are often hard, brittle, and angular. Inclusions located away from the flash-line are typically suspected of being an oxide inclusion. Oxide inclusions may appear distinctly brighter or wider than other flash-line indications.

Illustration 101

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Example of an oxide stringer.

Magnetic Particle Inspection The crankshaft needs several inspections for cracks. A first inspection may show fine cracks in the journal. After the crankshaft is ground, a second inspection can show that the cracks were ground out. Crankshafts should be inspected for cracks after any operation that includes straightening, grinding, or polishing. Inspect the journals, oil holes, and the fillets for cracks. Note: The crankshaft must be cleaned thoroughly prior to beginning any inspection work. Dirty crankshafts can contaminate the solution and mask indications. Equipment and Tooling Table 5 Required Tooling Equipment for magnetic particle inspection Vee Blocks

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Illustration 102

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Machine for magnetic particle inspection

The magnetic particle inspection process must be used for crankshafts. Machines that use alternating current (AC) work better at detection than direct current (DC). The machine must utilize a carrier solution with the magnetic particles. The magnetic particles must be seen under ultraviolet light.

Illustration 103

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The machine must be able to magnetize the crankshaft with contacts and a magnetizing coil.

Illustration 104

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The machine adapted for larger crankshafts.

The machine must be large enough to hold all crankshafts that will be inspected.

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Illustration 105

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Carrier solution with magnetic particles

The carrier solution must not be seen under ultraviolet light. Follow the recommendations from the manufacturer for mixing the carrier solution with the magnetic particles. The solution must be mixed thoroughly by the pump. Contaminated solution must be replaced following the manufacturer recommendation. Magnetic Particle Techniques

Illustration 106

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Circular Magnetization Method (Head Shot) - A circular magnetic field is utilized for locating defects in a longitudinal orientation. The technique is performed by securing the test part between the head stocks and energizing the part end to end.

Illustration 107

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Longitudinal Magnetization Method (Coil Shot) - A longitudinal magnetic field is utilized for locating defects in a transverse orientation. The technique is performed by energizing a coil surrounding the test part. Continuous Magnetism Method - The continuous magnetism method is utilized by magnetizing the test part immediately after or during the application of the carrier solution. Residual Magnetism Method - The residual magnetism method is utilized by magnetizing the test part before applying the carrier solution. In this manner the technician is relying upon the residual magnetism in the test part to attract particles. Procedure for Crankshaft Magnetism Inspection

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Illustration 108

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Inspection Microscope

Illustration 109

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Rests for crankshafts

Illustration 110

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Crankshaft on rests

1. Use the correct vee blocks and use the rests to ensure that the crankshaft is level.

Illustration 111

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Rollers

2. The crankshaft must be level for the magnetizing coil can move along the crankshaft. Use proper rollers making rotation possible.

Illustration 112

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Set up for crankshaft with copper pads

Illustration 113

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Using a spacer

NOTICE Be careful when utilizing a spacer on either end of a crankshaft. Once the inspection is completed, check the ends of the crankshaft for damage from sparks.

3. The ends of the crankshaft must make good contact with the pads. Use a spacer only when necessary. The use of braided copper pads helps to prevent sparks. 4. Magnetizing the crankshaft for 0.5 to 1.0 seconds is adequate. Magnetize and thoroughly inspect the crankshaft using both the head shot and coil shot techniques. Utilize the instructions given in Step 5 and Step 9 for amperage guidelines. Note: Alternating current concentrates the magnetic field at the part surface.

Illustration 114

g01444793

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Controls for current

5. Adjust the controls on the machine for the correct longitudinal current. Refer to Table 6 for current recommendations. There are various methods to determine adequate amperage: Use a QQI or other manufactured defect gauge. Use a hall effect meter to achieve a minimum 30 gauss at the inspection surface Table 6 Current Recommendations for the Head Shot Method Main Journal Diameter

Approximate Amperage (AC)

Approximate Amperage (HWDC, FWDC)

Up to 51 mm (2.0 inch)

700 A

1000 A

Up to 102 mm (4.0 inch)

1500 A

2000 A

Up to 153 mm (6 inch)

2300 A

3000 A

Up to 203 mm (8 inch)

3500 A

4000 A

6. Ensure that the concentration is correct. Thoroughly mix the carrier solution.

Illustration 115

g01444821

7. Longer crankshafts are commonly processed in sections. More than one section can be inspected on smaller crankshafts. Pour the carrier solution along a section of the crankshaft. Immediately apply the current for 0.5 to 1.0 seconds while the solution drains. This technique represents the continuous method.

Illustration 116

g02899063

An example of a linear indication.

8. Inspect the crankshaft for cracks. Direct current magnetizing works best for finding linear indications.

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Illustration 117

g01444946

9. Switch the current setting to go through the magnetizing coil. Adjust the controls on the machine for the correct coil shot current. Refer to Table 7 for current recommendations. There are various methods to determine adequate amperage: Use a QQI or other manufactured defect gauge. Use a hall effect meter to achieve a minimum 30 gauss at the inspection surface Note: Assume a strong field approximately 30.5 cm (12 inch) on either side of the coil. AC coils are often limited to approximately 1000 amps. Alternating current concentrates the magnetic field at the part surface. Table 7 Current Recommendations for the Coil Shot Method Main Journal Diameter

Approximate Amperage (AC) Three turn coil

Approximate Amperage (AC) Five turn coil

Up to 51 mm (2.0 inch)

2000 A

1000 A

Up to 102 mm (4.0 inch)

3000 A

2000 A

Up to 153 mm (6 inch)

4000 A

3000 A

Up to 203 mm (8 inch)

5000 A

4000 A

Illustration 118

g06282090

10. Longer crankshafts are commonly processed in sections. More than one section can be inspected on smaller crankshafts. Pour the carrier solution along a section of the crankshaft. Immediately apply the current for 0.5 to 1.0 seconds while the solution drains. This technique represents the continuous method.

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Illustration 119

g02899080

This circumferential indication represents a crack.

11. Inspect the crankshaft for cracks. The coil shot inspection will show the indications that go around the circumference of the journal.

Illustration 120

g01445121

Indicator of magnetic fields

12. Refer to the proper instructions for the machine to remove magnetism. The magnetic level must be less than five gauss. Use an indicator for magnetic fields to measure magnetism. 13. Thoroughly clean the crankshaft. 14. Remove the crankshaft from the machine. 15. Put a layer of oil on the crankshaft for protection.

Measurement Requirements NOTICE Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Important Areas of Inspection Specific areas are shown in different colors according to importance. Table 8 Red or A

Yellow or B

Green or C

Orange or D

White or E

No cracks allowed. No open indications allowed.

No cracks allowed. No open indications allowed.

No cracks allowed. Open indications smaller than 28.5 mm (1.12 inch) or wider than 0.15 mm (0.006 inch) permitted.

No cracks allowed.

No cracks allowed.

Fillet Area Inspection Crankshafts with Fillet Radii Greater than 5.23 mm (0.206 inch)

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Illustration 121

g02897736

(1) Fillet (2) Machined Journal Sidewall

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Illustration 122

g02897776

(1) Machined Journal Sidewall (2) Fillet

Crankshafts with Fillet Radii Greater than 5.23 mm (0.206 inch)

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Illustration 123

g02897802

(2) Fillet (11) Machined Journal Sidewall

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

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Illustration 124

g02897841

(1) Machined Journal Sidewall (2) Fillet

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Illustration 125

g02899116

(1) Machined Journal Sidewall (2) Fillet

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Illustration 126

g02899716

(1) Machined Journal Sidewall (2) Fillet

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Illustration 127

g02899797

(1) Machined Journal Sidewall (2) Fillet

Fillet Area Inspection Examples

NOTICE Do not use a crankshaft that has a crack affecting the fillet area.

Illustration 128 Crack through the fillet area Do not reuse the crankshaft.

g01446201

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Illustration 129

g02899836

Crack through the fillet area Do not reuse the crankshaft.

Illustration 130

g01446214

Crack through the fillet area Do not reuse the crankshaft.

Illustration 131

g01446243

The indication at the junction of the fillet and the journal is a crack. Do not reuse the crankshaft.

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Illustration 132

g02899858

Fine fillet cracks Do not reuse the crankshaft.

Illustration 133

g02899881

Fine fillet cracks Do not reuse the crankshaft.

Illustration 134

g01446375

Fine cracks in fillet between two rod journals Do not reuse the crankshaft.

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Illustration 135

g02899896

Fine cracks in fillet between two rod journals Do not reuse the crankshaft.

Oil Hole Inspection The nominal dimension outside the chamfer of the rod journal oil holes must be enlarged if the flash-line is in line with the oil hole.

Illustration 136

g02899919

The nominal 3.1 mm (0.12 inch) dimension outside the chamfer must be enlarged to 9.6 mm (0.38 inch) for the connecting rod journal oil holes if the flash-line is in line with the oil hole.

Illustration 137

g06282096

Example of flash line inline with oil hole.

Oil Hole Area Inspection Examples The oil holes in the connecting rod journal are in line with the flash-line on these engines: D339, D342, D353, and D399. r080crc15 Caterpillar: Confidential Yellow

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Illustration 138

g01446468

Small crack in oil hole Do not reuse the crankshaft.

Illustration 139

g01446471

Small crack in oil hole Do not reuse the crankshaft.

Illustration 140

g01446624

Fine cracks in the oil hole Do not reuse the crankshaft.

Illustration 141

g01446631

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Small cracks near the chamfer area Do not reuse the crankshaft.

Journal Area Inspection Journal Area Inspection Examples Grind and polish the crankshaft to the next journal size if required. The crankshaft can be reused if there are no open indications within 3.0 mm (0.12 inch) of the chamfer area. There must be no cracks. After a grind and polish procedure, reinspect the crankshaft. Ensure that all service cracks have been fully removed. Ensure that there are no grinder cracks introduced.

NOTICE Check the hardness of all the journals after grinding.

Illustration 142

g01446673

This open indication is a scratch. The scratch is verified by the position of the indications combined with smooth edges. Reuse the crankshaft.

Illustration 143

g01446719

These indications are scratches. The scratches are verified by the position of the indications combined with smooth edges. Reuse the crankshaft.

Illustration 144

g01446757

This indication is very fine and is representative of an inclusion or scratch and not a crack. Reuse the crankshaft.

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Illustration 145

g01447204

The ends of this horizontal indication travel at a 45° angle, this indication is typical of a torsional crack. Do not reuse the crankshaft.

Illustration 146

g02856537

Multiple cracks. Do not reuse the crankshaft.

Illustration 147

g06282098

This crack in the journal is connected and cannot be ground out. Do not reuse the crankshaft.

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Illustration 148

g01447029

The cracks are caused by heat. Do not reuse unless fully removed.

Illustration 149

g01447036

The cracks are caused by heat. Do not reuse unless fully removed.

Illustration 150

g06282102

The cracks are caused by heat. Do not reuse unless fully removed.

Illustration 151

g06282104

The cracks are caused by heat. Do not reuse unless fully removed.

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Illustration 152

g01447147

Larger cracks cannot be ground out. Do not reuse the crankshaft.

Illustration 153

g01447163

Cracks remain after a crankshaft has been ground. Do not reuse the crankshaft.

Illustration 154

g06282105

The fine indication is visible after the crankshaft has been ground. The indication is not a crack and not in a critical area therefore can be reused. Reuse the crankshaft.

Web Area Inspection Do not reuse a crankshaft that has any indications in a “red zoned” web area. Do not reuse a crankshaft that has an open indication or a crack in the “yellow zoned” web area. Closed indications are permissible in this area.

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Illustration 155

g02856558

Series 1100, Series 3100, Series 3208 and, Series 3508 engines (4) Machined Journal Sidewall (1) “Red” Lightening Hole Area (2) “Yellow” Web Area (3) Rough Journal Sidewall (5) “Red” Fillet Area (6) “Yellow” Fillet Area (7) “Yellow” Lightening Hole Area

Illustration 156

g02856541

The shaded areas are between the main and pin journal centerlines. There are no cracks allowed in the shaded portion of the web area. (A) Accept (R) Reject

Web Area Inspection Examples

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Illustration 157

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

g02901580

Illustration 158

g02901581

Groups of indications in the webs are normal. This indication is not a crack and is in the white zone. Reuse the crankshaft.

Illustration 159

g02856539

This crack goes into a machined journal sidewall area. Do not reuse the crankshaft.

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Illustration 160

g01447709

This indication is on the web on the crankshaft and is not a crack. The indication does not touch the lightening hole. The indication does not go into a machined journal sidewall surface. Therefore the crankshaft can be reused. Reuse the crankshaft.

Illustration 161

g01447755

Illustration 160 shown under white light. This indication is on the web and is not a crack. The indication does not touch the lightening hole. The indication does not go into a machined journal sidewall surface. Therefore the crankshaft can be reused. Reuse the crankshaft.

Illustration 162

g02901601

These forging laps are acceptable and can be any shape. Forging laps can be open or closed indications. Forging laps are often not as bright and distinct as a crack. Lap indications must not go more than 1.0 mm (0.04 inch) into a machined journal surface. Reuse the crankshaft.

Illustration 163

g02901638

These forging laps are acceptable and can be any shape. Forging laps can be open or closed indications. Forging laps are often not as bright and distinct as a crack. Lap indications must not go more than 1.0 mm (0.04 inch) into a machined journal surface. Reuse the crankshaft.

Illustration 164

g01447879

The lap indication goes around a corner. The area is in the counterweight which is away from any machined journal surface. Reuse the crankshaft.

Illustration 165

g01447915

The indication was ground out in this large area. Make sure that any sharp edges are smooth. Reuse the crankshaft.

Illustration 166

g01447830

The indication goes into a groove. Grinding revealed this indication was not a crack or a deep forging lap. Reuse the crankshaft.

Illustration 167

g06282109

A closer view of Illustration 166, highlighting the groove and the indication.

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Reuse the crankshaft.

Illustration 168

g01447798

This indication is not a crack. Reuse the crankshaft.

Illustration 169

g06282110

This indication is not a crack. Reuse the crankshaft.

Illustration 170

g06282111

Crack in the lightening hole area. Do not reuse the crankshaft.

Illustration 171

g01447689

Cracks in the lightening hole area Do not reuse the crankshaft.

Illustrations 172 through 174 show that some shallow forging laps can be seen in several webs. These forging laps typically follow the shape of the crankshaft or the flash line. If there are no cracks, then the crankshaft can be used.

Illustration 172 g01448020

Illustration 173 g06282115

Illustration 174 g01448070

Flange, the Shaft, and the Keyway Area Inspection

Illustration 175 g01448104

Illustration 176 g06282118

Illustration 177 g06282122

Illustration 178 g06282123

Illustration 179 g01448289

Illustration 180 g06282126

Illustration 181 g06282127 (1) Front edge of keyway

Flange, the Shaft, and the Keyway Area Inspection Examples

Illustration 182

g02901696

Do not reuse the crankshaft. (2) Cracks at the end of the keyway (3) The gear is located in an area that has a crack.

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Illustration 183

g06282131

Do not reuse the crankshaft. (3) The gear is located in an area that has a crack.

Suppliers of Magnetic Particle Test Equipment Note: Not all the manufacturers that follow have machines that can hold the larger Caterpillar crankshafts. Magnaflux 3624 West Lake Avenue Glenview, Illinois 60026 (847) 657-5300 (800) 421-1569 (Fax) www.magnaflux.com Magwerks 501 Commerce Dr. Danville, IN 79455 (317) 241-8011 (317) 241-8015 (Fax) www.magwerks.com Gould-Bass 1431 W. Second Street Pomona, CA 91766 (909) 623-6793 (909) 629-1467 (Fax) www.gould-bass.net

Measurement Requirements NOTICE Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Procedure to Measure Used Crankshafts for Bend Tooling Setup

Illustration 184 g06282179 6V-7926 Dial Indicator

Use the 6V-7926 Dial Indicator for all measurements.

Illustration 185

g03082281

Typical air gauge and calibration blocks used for crankshaft measurement.

Illustration 186

g03102678

Air gauge tooling properly set up.

Illustration 187 g03061140 5P-8637 Supports

Illustration 188

g03081059

Crankshaft support with rollers.

Crankshaft supports are sometimes referred to as V blocks. Place two crankshaft supports on a machined granite slab, a surface plate, or a concrete floor. Do not use a work bench. The weight of the crankshaft may bend the r080crc15 work bench resulting in inaccurate measurements. Caterpillar: Confidential Yellow https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledp… 71/139

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Illustration 189

g06282180

The magnetic base of the dial indicator must be held stationary with a piece of steel with three pads welded to the bottom.

Use a piece of steel to hold the magnetic base for the dial indicator. Weld three identical steel pads 120 degrees apart to the bottom of a piece of steel. 1. The crankshaft supports should be aligned before and after the crankshaft has been placed on the supports. Align the crankshaft supports such that both bases are an equal distance from an established reference point. A secured metal strip that is parallel to the edge of a surface plate or a blue line on concrete are good reference points.

Illustration 190

g06282182

Position the crankshaft supports underneath the main journal bearings at the ends of the crankshaft.

2. Place the crankshaft with the crankshaft supports underneath the main journals at the ends of the crankshaft. Refer to Illustration 190. Check the crankshaft supports and the crankshaft to ensure that the supports are stationary and aligned. The crankshaft must rotate in the supports, but not move horizontally. Note: Ensure that the oil hole does not come in contact with the center of the crankshaft support. When possible, keep the crankshaft support to one side of the crankshaft journal but not into the fillet. The diameter of the crankshaft journal should be the only point of contact with the crankshaft support. Note: Use the same reference point used in Step 2 to align the base of the dial indicator. Using this reference point will ensure a more efficient procedure for setup and inspection.

Illustration 191

g06282184

The 5P-8637 Supports are positioned under the main journal bearings on the end of the crankshaft

3. Place the magnetic base of the dial indicator on the piece of steel. Put the contact point for the dial indicator on one of the main journals that are next to a crankshaft support. Refer to Illustration 191. Position the dial indicator so the stem will not contact the oil hole. The contact point must be perpendicular to the bearing surface. 4. Once the adjustments are made, rotate the crankshaft 360 degrees to ensure that the travel of the dial indicator is sufficient. Adjust the dial indicator to zero. Note: This procedure must be performed every time the crankshaft supports have been moved.

Procedure for Performing the Measurement The procedure to be described is referred to as the step in method. This specific example is for a crankshaft with seven journals, but the basic principle applies to all crankshafts. Table 9 Example V-Block and Measurement Positioning for a 16 Cylinder Engine V-Block Journal Position

Journal being measured

1 and 9

2 and 8

2 and 8

3 and 7

3 and 7

4 and 6

4 and 6

5

On all crankshafts, start by placing the 5P-8637 Supports on the farthest outside main journals and work inward. Take the Total Indicator Runout (TIR) measurement on the next interior main bearing journals directly next to the crankshaft supports. Do not attempt any additional TIR measurements on other journals at this time. For example: If the crankshaft supports are on journals 1 and 7, then only journals 2 and 6 will be measured. When the crankshaft supports are located on journals 3 and 5, only journal 4 will be measured. Refer to Table 9 for an example. If you attempt to record the TIR for journal number 4 when the crankshaft supports are positioned at journals number 1 and 7 (or 2 and 6), you will take an inaccurate measurement because of sag at the center of the crankshaft. (The same is true when the crankshaft supports are located on journals 3 and 5 and you attempt to measure journals 1 and 7.) Note: The procedure for the 20 cylinder 359-0941 Crankshaft positions the V-blocks on main journals 1 and 11. The TIR for main journals 2 through 10 are then measured without moving the V-block position. The procedure used for the remaining C175 crankshafts is referred to as the step in method. This specific example is for a crankshaft with 7 journals, but the same principle applies to the 16 cylinder and 20 cylinder C175 crankshafts. On these crankshafts, you will be placing the V-blocks on a specific main bearing journal and taking the TIR measurement on the main bearing journals to the INSIDE and next to the V-blocks. Do not make ANY other TIR measurements besides the ones taken on the journals to the INSIDE next to the V-blocks. For example: Do NOT measure journals 3, 4, or 5 if the V-blocks are on journals 1 and 7. You should only be measuring journals 2 and 6. When the V-blocks were on journals 3 and 5, you should only be measuring journal 4. Note: The 3406, 3456, C15, and C18 crankshafts have a different TIR than other crankshafts and have different considerations for checking for straightness. Refer to "Special Considerations for 3406, 3456, C15, and C18 Crankshafts" later in this document. Note: Assume that the tooling was set up on the main journal. r080crc15 Caterpillar: Confidential Yellow

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Illustration 192

g06282544

5P-8637 Supports on journals 1 and 7 while measuring TIR of journals 2 and 6.

1. Position one support under each main journal on the far ends of the crankshaft. Refer to Illustration 192, the crankshaft supports are located on the main journals 1 and 7. 2. With the dial indicator set-up on journal number 2, rotate the crankshaft 360 degrees and record the Total Indicated Runout (TIR). The TIR is the difference between the highest readings and the lowest readings on the dial indicator while the crankshaft is being rotated. Note: If an oil hole comes in contact with a crankshaft support, the TIR will be incorrect. Try to keep the crankshaft supports to one side of the crankshaft journal, but not into the fillet, so the diameter of the crankshaft journal is the only point of contact with the crankshaft support. 3. Move the dial indicator to journal number 6, and zero the dial indicator again. Rotate the crankshaft 360 degrees and record the TIR

Illustration 193

g06282546

5P-8637 Supports on main journals 2 and 6 while measuring TIR of journals 3 and 5.

4. Move the crankshaft supports towards the center of the crankshaft one journal to the main journals 2 and 6. Refer to Illustration 193. 5. Position the dial indicator on journal number 3 and zero the dial indicator. Rotate the crankshaft 360 degrees and record the total TIR. Repeat this step for journal number 5.

Illustration 194

g06282550

5P-8637 Supports on main journals 3 and 5 while measuring TIR of journal 4.

6. Move the crankshaft supports towards the center of the crankshaft one journal to the main journals 3 and 5. Refer to Illustration 194. 7. Position the dial indicator on journal 4 and zero the dial indicator. Rotate the crankshaft 360 degrees and record the total TIR. Note: If there are two maximum points during the measurement of TIR, use an outside micrometer. Check for an out of round main journal.

Special Considerations for 3406, 3456, C15, and C18 Crankshafts A different measuring procedure must be used for the 3406, 3456, C15, and C18 crankshafts. These crankshafts will use an adjacent journal check and a stack up tolerance check. You will be taking a TIR reading on main bearing journal number 4 in each check. If the TIR readings on both checks are within specifications that are listed, the crankshaft is good. Adjacent Journal Check

Illustration 195

g06282556

Adjacent journal reading of main bearing number 4 with the crankshaft supports on journals 3 and 5

The adjacent journal check should be performed with the crankshaft supports positioned on main bearing journals 3 and 5. Perform the TIR reading on main bearing journal number 4 only. The TIR on main bearing journal number 4 should not exceed 0.18 mm (0.007 inch). Stack-Up Tolerance Check

Illustration 196

g06282561

Stack up TIR reading on main bearing journal number 4

This check should be performed with the crankshaft supports positioned on main bearing journals 1 and 7. The TIR should be measured on bearing journal number 4 only. The TIR on journal number 4 should not exceed 0.54 mm (0.021 inch).

Special Considerations for C175 Crankshafts The following chart lists the position of the V-blocks and which corresponding journal that should be measured. Table 10 C175-20 V-block Journal Position

Journal to be Measured

1 and 11

2 and 10

2 and 10

3 and 9

3 and 9

4 and 8

4 and 8

5 and 7

5 and 7

6

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C175-20 Part Number 359-0941 1 and 11

2 through 10 C175-16

V-block Journal Position

Journal to be Measured

1 and 9

2 and 8

2 and 8

3 and 7

3 and 7

4 and 6

4 and 6

5

The TIR for C175 main bearing journals is 0.13 mm (0.005 inch). Since the journal that is resting on the V-block is considered "zero", the journal directly next to the Vblock and to the INSIDE of the V-block cannot have a TIR that exceeds 0.13 mm (0.005 inch). In the following example, the TIR for journal 6 was 0.1778 mm (0.007 inch) when the V-blocks were resting on journals 3 and 7. Since the spec for the journal TIR for this crankshaft is 0.13 mm (0.005 inch), this crankshaft is out of specs.

Illustration 197

g06283124

Example of a measured crankshaft. The C175-16 crankshaft is shown

Illustration 198

g06283131

20 cylinder 359-0941 Crankshaft is shown TIRs that are shown are the maximum allowable TIR for each journal. The TIRs are shown in INCHES

The TIR for the 20 cylinder 359-0941 Crankshaft will be taken with the V-blocks resting on main journals 1 and 11. Measure the remaining main journals without moving the V-blocks from this position. The TIR increases towards the center of this particular crankshaft to compensate for any deflection that may occur due to the length of the crankshaft.

Procedure to Measure Crankshafts after the Bearing Journals have been Ground If a crankshaft is reground, journals must be in alignment with other surfaces of the crankshaft. The TIR for any of the measurements that follow cannot be more than specifications for the respective engine platform. The crankshaft cannot be used again if the measurements are greater than specifications. Grind the crankshaft to the next standard size and then measure the crankshaft again.

Measurement of TIR on Hub Circumference or Flange for Flywheel

Illustration 199 g03060097

1. Put the crankshaft supports under the number two and six main journals. Put the contact point of the dial indicator on the circumference of the flywheel pilot. Refer to Illustration 199. Note: The contact point must not be in the wear groove of the rear crankshaft seal. Measuring the circumference of the front flange.

Illustration 200 g01394439 Measuring TIR

Illustration 201 g06282565 Measuring TIR

2. The contact point must be perpendicular to the surface and at the approximate centerline of the crankshaft. For all engines with a pilot hub for the flywheel, put the contact point for the dial indicator on the hub of the crankshaft. Refer to Illustrations 200 and 201. 3. Turn the crankshaft 360 degrees and check TIR.

Measurement of TIR on Flange for Pulley or Damper and Flywheel

Illustration 202

g01394669

The measurement of the flange face for a pulley or a damper on a lathe. The measurement can also be made using 5P-8637 Supports if a lathe is not available.

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Refer to "Preventing Axial Movement of the Crankshaft" section of this guideline. Remove the 5P-4163 Indicator Contact Point. Install the 7H-1940 Universal Attachment to the dial indicator. Put the point for the universal attachment on the face of the flange for the pulley or the damper. Refer to Illustration 204. The point of the universal attachment must be near the outer circumference of the flange face so that the point will not hit the holes in the crankshaft. Turn the crankshaft 360 degrees and check TIR. Use the same procedure for the face of the flywheel flange.

Measurement of TIR on Main Bearing Journals Measure the main bearing journals. Refer to "Procedure to Measure Used Crankshafts for Bend" section of this guideline. The maximum TIR specification for the main bearing journals of most reground crankshafts is 0.13 mm (0.005 inch). The maximum TIR specification for the main bearing journals for 3406, 3456, C15, and C18 crankshafts are 0.18 mm (0.007 inch).

Measurement of TIR on Front Flange, Straight Front Shaft, or Hub Circumference Perform the steps outlined under "Measurement of TIR on Hub Circumference or Flange for Flywheel" section of this guideline 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 TIR. Do not allow the contact point to hit a keyway.

Measurement of TIR on Tapered Front Shaft

Illustration 203

g01394721

Measuring the tapered surface

Refer to "Preventing Axial Movement of the Crankshaft" section of this guideline. Put the contact point for the dial indicator near the end of the tapered surface. Refer to Illustration 203. The contact point must be perpendicular to the tapered surface and at the approximate centerline of the crankshaft. Turn the crankshaft 360 degrees and check TIR. Do not allow the contact point to hit a keyway.

Preventing Axial Movement of the Crankshaft The remainder of the measurements can only be done with accuracy if all axial movement of the crankshaft is prevented. One method is installing smaller crankshafts and medium crankshafts on a lathe in the center of the crankshaft. Note: Do not use a lathe to check TIR of the main bearing journals of a large crankshaft. The weight of the crankshaft can cause an incorrect TIR.

Illustration 204

g01394835

Crankshaft with a steel ball that is pushed against a heavy steel object

A second method is by using supports with a hardened steel ball that has the diameter of 19.7 mm to 22.4 mm (0.62 inch to 0.88 inch). Put the steel ball in a machined center on the front end of a crankshaft. Push the crankshaft and the steel ball against a heavy steel object. Refer to Illustration 204. Put oil on the steel ball. Do not move or dent the heavy steel object when pressure is applied. The crankshaft must be held against the steel object while the measurements are taken.

Determine if a Bent Crankshaft Can Be Straightened Note: Straightening of C175 crankshafts is not approved. Note: Crankshafts from C9, C10, C11, C12, C13, and C15 series engines should not be straightened. If the crankshafts from these engines are bent more than the allowable specifications that are listed, then the crankshaft should be replaced. Follow this procedure to measure the overall TIR at the center main bearing.

Illustration 205

g06282571

The crankshaft is installed on supports. Measure the TIR at the center main journal bearing only. This measurement will determine if the crankshaft can be straightened safely.

1. Perform steps 1 through 4 of "Tooling Setup" section of this guideline. 2. Place the contact point for the dial indicator on the center main bearing. Refer to Illustration 205. The contact point must be to the side of the oil hole, perpendicular to the bearing surface, and at the approximate centerline of the crankshaft. 3. Rotate the crankshaft to 360 degrees after the adjustments have been made. Moving the crankshaft ensures that there is sufficient travel for the dial indicator. Adjust the dial indicator to zero. 4. Turn the crankshaft 360 degrees and check the dial indicator. Make a note of TIR. 5. The crankshaft can be straightened if TIR is within the specifications found within the appropriate specification.

Straightening a Bent Crankshaft Note: Straightening of C175 crankshafts is not approved. Crankshafts from C9, C10, C11, C12, C13, and C15 series engines should not be straightened. If the crankshafts from these engines are bent more than the allowable r080crc15 specifications that are listed, then the crankshaft should be replaced.

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Grinding the bearing surfaces is one method that is used to straighten bent crankshafts. Although grinding the surfaces is easier, grinding is limited because the bearing surfaces must be completely ground. The finished size must not be smaller than the next available undersize bearing.

Equipment Needed to Straighten Bent Crankshafts Oven Heating the crankshaft with an oven is crucial. The oven must heat the crankshaft to 177° to 232° C (350° to 450° F). To prevent cracks, do not straighten the crankshaft at room temperature. Temperature of the crankshaft can be measured with a 164-3310 Infrared Thermometer. The temperature can also be checked with temperature recording crayons. Hydraulic Press for Straightening A hydraulic press is necessary to straighten the crankshaft. The press must be equipped with one or more dial indicators to measure TIR on the main bearing journals while the crankshaft is in the press. Hydraulic presses are available from the following corporations. Eitel Presses Inc. 97 Pinedale Industrial Road Orwigsburg, PA 17961 http://www.eitelpresses.com/ Phone 570 366 0585 Fax 570 366 2536 Dake Corporation 724 Robbins Rad Grand Haven, MI 49417 http://www.dakecorp.com/ Phone 800 937 3253 Fax 800 846 3253

NOTICE To prevent damage to the crankshaft, the anvil and the ram must be made from soft steel or copper and narrower than the bearing journal. The use of an anvil or a ram that is wider than the bearing journal can damage the fillet. Do not use Crankshaft Supports as a support for straightening the crankshaft.

Equipment for Magnetic Particle Inspection A crankshaft that has been straightened must be checked for cracks. The magnetic particle procedure must be used after straightening the crankshaft. Machine for Shot Peening Shot peening the fillet of the bearing journal on some crankshafts may be necessary. This procedure must be done after the crankshaft has been straightened.

Procedure to Straighten Bent Crankshafts Note: Straightening of C175 crankshafts is not approved.

NOTICE This procedure is not applicable for micro alloyed crankshafts.

1. Heat the crankshaft in the oven for a minimum of 1 1/2 hours. Do not use a torch. A torch does not produce an even heat. Straighten the crankshaft when the temperature is between 177°C to 232°C (350°F to 450°F). 2. Put anvils on each side of the main journal that will be straightened. Check for burrs on the anvil and the surfaces of the ram. 3. Turn the crankshaft so that the ram can make contact at the high point. Put a dial indicator in position to measure the deflection of the crankshaft. 4. Carefully put the ram against the main journal that will be straightened. 5. Put a small amount of pressure on the crankshaft and release the ram. The deflection during this step must not be more than one half of the TIR measured in "Procedure to Measure Used Crankshafts for Bend" section of this guideline. 6. Check the straightness of the crankshaft. Put the contact point for the dial indicator against the main bearing journals. The contact points must be to the side of the oil holes. Turn the crankshaft and look at the dial indicator. Apply more pressure and increase the deflection if the TIR on the main bearing journals next to the Crankshaft Supports is more than 0.13 mm (0.005 inch). The TIR for 3406, 3456, C15, and C18 crankshafts must not be more than 0.18 mm (0.007 inch). After increasing the deflection, measure the TIR again. 7. Increase the amount of pressure in small increments, until the TIR on this journal meets the specifications. Be careful not to use too much pressure since excessive r080crc15 pressure can cause the crankshaft to bend in the opposite direction. Cracks will occur if the crankshaft is bent in the opposite direction. Caterpillar: Confidential Yellow https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledp… 76/139

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8. Repeat step 3 through 6 to straighten any other bent areas on the crankshaft. 9. Measure the amount of bend in the crankshaft according to the directions in "Procedure to Measure Used Crankshafts for Bend" section of this guideline. 10. Check the crankshaft for cracks. Especially check the fillets of the journal on the opposite side of the ram. Use the magnetic particle inspection.

Crankshaft Measurement Preparing for Crankshaft Measurement

Illustration 206

g03060262

A crankshaft installed on three 5P-8637 Supports.

Place the crankshaft on a minimum of three supports. Place two supports on each end and at least one at the center of the crankshaft to eliminate sag. Refer to Illustration 206. The blocks should be on a sturdy work surface to hold the crankshaft during the following procedures. Use an air gauge for taking measurements. If an air gauge is not available, then an outside micrometer with a vernier scale and a friction thimble must be used. The micrometer must have a graduation of 0.001 mm (0.0001 inch). For greatest accuracy, use a gauge block to adjust the micrometer before each crankshaft is checked.

Procedure to Check for Out Of Round and Diameter

Illustration 207

g01396635

Measuring for out of round of the journal diameter

1. Air gauges are the preferred tooling however, outside micrometers are acceptable. Measure the rods and mains journal diameter at top dead center TDC. 2. Measure the rod and main journals 90 degrees from TDC. Refer to Illustration 207. 3. Be sure to keep the tooling out of the oil hole and the immediate area around the oil hole where the journal surface is lower. The dimensions must be no greater than the specifications for the respective engine platform. The diameter of two rod journals can be 0.005 mm (0.0002 inch) under the minimum specifications. Note: If the crankshaft has been ground undersize, subtract the undersize dimension of the crankshaft from the minimum or maximum dimensions. Refer to the Reuse and Salvage Guideline specifications for the respective engine platform for the correct dimensions.

Procedure to Check for Taper

Illustration 208

g01397503

Taking the measurement on one side of the journal

Air gauges are the tooling for measuring, however outside micrometers with a graduation of 0.001 mm (0.00004 inch) are acceptable. Measure the diameter of the rod journal at TDC next to but not on each fillet . Measurements must be taken on both sides of the journal. Refer to Illustration 208. The difference of the two measurements must not exceed the dimensions of taper. Example The diameter of the main bearing journal of a 2P-2842 Crankshaft on a 3306 Engine Table 11 3306 Crankshaft One fillet

88.890 mm (3.4996 inch)

Other fillet

88.877 mm (3.4991 inch)

Difference

0.013 mm (0.0005 inch)

The difference is less than the reusable specification of 0.015 mm (0.0006 inch) for maximum taper. The journal has acceptable taper.

Procedure to Check for Wear of the Thrust Face

Illustration 209

g01397566

Measuring the wear of the thrust face with a micrometer

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Illustration 210

g06282595

The distance between thrust surfaces that should be measured

Use an inside micrometer. Measure the distance between the thrust surfaces. Refer to Illustration 209. The measurement between the thrust faces must be between the maximum and the minimum reusable specifications. Note: When the crankshaft is installed, check for the correct crankshaft end play.

Procedure to Check Journal Straightness Follow this procedure when specific measurements of journal straightness are necessary. The following tooling is required for this test. Refer to Illustration 212. Table 12 Tooling for Measuring Profile 3P-1568 Dial Indicator or a similar indicator with the accuracy of 0.002 mm (0.0001 inch) 7H-1941 Dial Indicator Base and 7H-1948 Swivel Post Snug Both parts are included in the 8S-2328 Dial Indicator Group. 7B-0337 Surface Plate 5P-8637 Vee Blocks

Illustration 211

g03103438

Crankshaft supports on a machined granite slab aligned with a machined straight edge.

1. Put the crankshaft supports on a concrete floor, a sturdy surface, or preferably a machined granite slab. Refer to Illustration 211. 2. Align the crankshaft supports with a machined straight edge and place the crankshaft on the supports. Ensure that the crankshaft is fully supported to eliminate any effects of sagging. Put a surface plate under the journal that will be measured.

Illustration 212

g01397606

Measuring the profile of the crankshaft

3. Adjust the dial indicator so the contact point will slide against the top of the journal that will be measured. 4. Adjust the dial indicator to zero at the highest point of the journal diameter. Move the dial indicator base on the surface plate to stroke the journal diameter horizontally at intervals of 3 mm (0.1 inch). Refer to Illustration 215.

Illustration 213 g06282600

5. Mark the location of each maximum indication reading on graph paper. When all the readings are taken, connect the points on the graph paper. Refer to Illustration 213.

Illustration 214

g06282616

The graph is acceptable because all points are within the width of 0.005 mm (0.0002 inch).

6. Place a second sheet of graph paper over the original piece to check that all the points are within the width of 0.005 mm (0.0002 inch). Refer to Illustration 214. If any points are outside this width, do not use the crankshaft again unless the crankshaft has been ground.

Illustration 215

g01398278

The crankshaft is installed between centers on a lathe. A 3P-1568 Dial Indicator is mounted on the tool holder. Use additional crankshaft supports to support the center of the crankshaft as needed.

Specific measurements of the journal profile can be taken by using both procedures. The procedures for checking a journal taper and profile are similar. The difference is placing the crankshafts on the centers of a lathe instead of supports. A 3P-1568 Dial Indicator is mounted on the tool holder. The contact point is then adjusted to slide against the main journal or the rod journal horizontally at 3.0 mm (0.12 inch) intervals. Refer to Illustration 215. Repeat the checking for taper procedure steps 5 and 6.

Equipment needed to Measure the Profile Several companies make equipment for measuring the profile. Taylor Hobson Ltd PO Box 36 2 New Star Road Leicester, LE4 9JQ, England www.taylor-hobson.com

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Phone 44 (0) 116 276 3771 Fax 44 (0) 116 246 0579 Mahr Federal Inc 1144 Eddy Street Providence, RI 02905 USA http://www.mahrfederal.com Phone 1-800-343-2050 Fax 1 (401) 784-3246

Procedure to Check the Fillet of the Journal There are two procedures for checking the radius of the fillet. Using the correct size of gauges is the preferred method. Use the bracket check method if the correct gauges are not available.

Procedure to Check Radius with Correct Gauge Follow this procedure to check the fillet of the journal after the crankshaft has been ground. 1. Use a decimal radius gauge with a range of 2 mm to 20 mm (0.095 inch to 0.75 inch). Compare the profile of the radius gauge with the profile of the fillet. If the radius gauge matches the fillet, there will be no space between the fillet and gauge. Refer to Illustration 217. A radius gauge in fractions can be used after the fractions are accurately converted to the decimal or metric equivalents. Radius gauges are available from several companies, one of them is listed below. Starrett www.starrett.com Phone (978) 249-3551 Fax (978) 249-8495 1. Put the correct size of radius gauge into the fillet. The radius gauge must come into contact with the center of the radius.

Illustration 216

g01398955

Measuring the radius of the fillet

Illustration 217

g01398957

The gauge is the correct size because the entire gauge is in contact with the radius of the fillet.

Illustration 218

g01398960

The radius is too large. The nose of the gauge is the only part of the gauge that contacts the fillet.

Illustration 219

g01398982

The radius is too small. The gauge is contacting the radius at the shoulders of the gauge.

2. The radius of the crankshaft must meet the specifications for the respective engine platform to be reused. Note: The appropriate engine platform specifications contain dimensions of radii before the peening operation. When possible, measure the fillets before the peening operation.

Procedure for Bracket Checking the Radii of the Journal Fillet The bracket check should be used when the exact gauges cannot be found. It will be necessary to measure the radius of the fillet by using other gauges that have a larger radius and smaller radius than the specified fillet. Refer to the following example. 1. Use a gauge that is smaller than the radius of the fillet. The nose of the gauge should contact the contour of the fillet. Refer to Illustration 218. If the shoulders of the gauge contact the fillet, then the gauge is larger than the fillet. 2. Use a gauge that is larger than the radius of the fillet. The nose of the gauge should not contact the contour of the fillet. Refer to Illustration 219. If the nose of the gauge contacts the fillet, the gauge is smaller than the fillet. 3. The bracket check method should show that the radius of the fillet is between the gauges. The crankshaft will give normal performance if the selected gauges are close to the specified radius of the fillet. The crankshafts must also meet the other physical requirements.

Special Checking Procedure for Specific Crankshafts The following information is used to check the radius of the rod and the main fillet. This information is only used for 1W-0400, 0R-5560, 0R-5474, and 0R-5164 crankshaft.

Illustration 220

g01401227

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Checking the radius of the rod (9) Max Point of Tangency with Sidewall (10) Typical Profile The profile of the fillet must fall within Zones (A, B, and C). The minimum radius in Zone (C) is 0.76 mm (0.030 inch). The minimum radius in Zone (B) is 4.88 mm (0.192 inch). The minimum radius in Zone (A) is 0.76 mm (0.030 inch). Double fillet intersection may occur in Zone (A). The intersection may contain a sharp peak. Refer to item (10).

Illustration 221

g01401286

Checking the radius of the main fillet (9) Max Point of Tangency with Sidewall (10) Typical Profile The profile of the fillet must fall within Zones (A, B, and C). The minimum radius in Zone (C) is 0.76 mm (0.030 inch). The minimum radius in Zone (B) is 2.34 mm (0.092 inch). The minimum radius in Zone (A) is 0.76 mm (0.030 inch). Double fillet intersection may occur in Zone (A). The intersection may contain a sharp peak. Refer to the Typical Profile.

Procedure to Inspect the Journal Procedure to Check the Hardness of the Journal Note: The hardness of the journals should be checked before any polishing operation. If a journal shows signs of high heat or grinding, check the hardness of journal. A Non-Destructive Test (NDT) method such as using an Equotip hardness testing tool can be used. Note: Do not use a sclerometer since this method may damage the crankshaft. Follow the recommendations of the manufacturer for use of the hardness tester. The hardness readings must be within these tolerances. Note: A soft spot may be found on a journal. Check both sides of the soft area if a soft area is discovered. If the hardness of the journal is within the specifications on both sides of the soft area, then the hardness of the journal is acceptable.

NOTICE On crankshafts such as the Series 3208 and Series 3300 families of engines, the rear half of the rear main journal and the rear fillet can be softer.

Procedure to Check Surface Texture

Illustration 222

g01396169

Example of profilometer checking the surface texture

Illustration 223 g06282620

The surface texture of bearing journals should be checked with 448-3698 Profilometer that will stroke the journal automatically. The radius of the stylus must be approximately 0.013 mm (0.0005 inch) and the unit should have a 0.80 mm (0.0315 inch) cutoff length. The travel direction of the surface texture measurement should be perpendicular to the grinding marks (A), as shown in Illustration 223. Note: Do not exceed the The maximum permissible surface roughness for bearing journals. Polish the journals if the surface roughness does not meet the specifications. The surface texture of the thrust face must be at least 0.45 mm (0.018 inch). Ensure that no wear steps or marks occur from grinding on the surface.

Specifications and Measuring Procedures for C4.4, C6.6, and C7.1 Engines Crankshaft Reusability and Salvage for C4.4 Engines The reuse of the main bearing cap fasteners at first assembly is allowed up to three times. New fasteners are required should more than four torque attempts be required during first assembly. For prototype build and assembly slave fixings must be used during the parent & fitted bore measurements, final assembly should then be completed with the original as supplied main bearing cap fasteners. If this tightening and reuse process is not followed, a main bearing cap or crankshaft failure may occur. Shell bearings can be reused provided there is no significant polish/scuffing on the bearing surface and that the bearing can be retained within the bearing housing (No significant loss in free spread) Thrust washers can be reused provided there is no significant polish/scuffing on the bearing surface. Note: For factory reworks where the crankshaft / main bearing caps are removed, new main bearing cap fasteners must be used.

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For both the cast and forged crankshafts the mains and large end journals can be reground. SGI Crankshafts = 2 regrinds ( 359-0715, 359-0716, 376-4076, 455-3692, 455-3693, and 455-3694) Steel Crankshafts = 3 regrinds ( 232-7400, 364-2829, and 466-4921). The regrinding depths are 0.250 mm (0.00984 inch), 0.510 mm (0.02008 inch), 0.760 mm (0.02992 inch). A journal surface texture of 0.25 µm (9.842520 µinch) Ra (Maximum) must be maintained. For both the cast and forged crankshafts, the crankshaft thrust faces can be reground once. For both the cast and forged crankshafts the crankshaft palm can be reground to the minimum of the specified sealing diameter tolerance 133.27 mm (5.24684 inch) / 133.32 mm (5.24881 inch). A crankshaft palm surface texture of 3.0 - 6.0 µm (118.1102 - 236.2205 µinch) Rz and 6.5 µm (255.9055 µinch) Rz Max must be maintained without spirals. Note: For Tier 2/3 Steel ( 232-7400 and 364-2829) components, a reapplication of the surface treatment is required on overhaul. Specifications for C4.4 Crankshafts

Illustration 224 g06282680

Table 13 C4.4 Crankshaft Re-Manufacture Specifications (Tier 2/3)( 359-0715 and 359-0716) ( 455-3692 and 455-3693) Dimension Number

Standard

0.25

0.51

0.190

Run Out

Surface Texture (Ra)

1

76.180 mm (2.9992 inch) 75.930 mm (2.9894 inch) 75.670 mm (2.9791 inch) to 76.159 mm to 75.909 mm to 75.649 mm (2.9984 inch) (2.9885 inch) (2.9783 inch)

Main 1: N/A

0.25 µm (9.842520 µinch)

2

68.01 mm (2.678 inch) to 67.76 mm (2.668 inch) to 67.50 mm (2.657 inch) to 67.99 mm (2.677 inch) 67.74 mm (2.667 inch) 67.48 mm (2.657 inch)

Main 2: 0.08

0.25 µm (9.842520 µinch)

N/A 3

40.48 mm (1.594 inch) Maximum

Main 3: 0.15

N/A

4

39.39 mm (1.551 inch) Maximum

Main 4: 0.08

N/A

5

44.22 mm (1.741 inch) to 44.15 mm (1.738 inch)

6

33.67 mm (1.326 inch) Minimum

7

133.27 mm (5.247 inch) Minimum

Minimum web Thickness Over Collar Face: SGI Iron Crankshaft End Float

Webbing 1: 18.98

44.60 mm (1.756 inch) Main to 44.53 mm 5: (1.753 inch) N/A

0.30 µm (0.01181 µinch) Ra (Maximum) N/A

Webbing 2, 3, 6, and 7: 18.53

N/A

N/A

Webbing 4 and 5: 19.28

N/A

3.0 - 6.0 µm (118.1102 - 236.2205 µinch) Rz 6.5 µm (255.9055 µinch) Rz Max Web 8: 22.83

Must be between 0.05 mm (0.00197 inch) and 0.38 mm (0.01496 inch)

N/A

Thrust Face Regrinding Depth

0.190 mm (0.00748 inch)

Thrust Face Surface Texture (5)

0.30 µm (0.01181 µinch) Ra (Maximum)

Crankshaft Balance

SGI Crankshafts ( 455-3692 and 455-3693)

50 g.cm, each end

Table 14 C4.4 Crankshaft Re-Manufacture Specifications (Tier 2/3) ( 232-7400 and 364-2829) Dimension Number

Standard

0.25

0.51

0.76

0.190

76.180 mm (2.9992 inch) to 76.159 mm (2.9984 inch)

75.930 mm (2.9894 inch) to 75.909 mm (2.9885 inch)

75.670 mm (2.97913 inch) to 75.649 mm (2.97830 inch)

76.420 mm (3.0087 inch) to 75.399 mm (2.9685 inch)

N/A

1

2

63.490 mm (2.4996 inch) to 63.470 mm (2.4988 inch)

63.240 mm (2.4898 inch) to 63.220 mm (2.4890 inch)

62.980 mm (2.4795 inch) to 62.960 mm (2.4787 inch)

62.730 mm (2.4697 inch) to 62.710 mm (2.4689 inch)

3

40.424 mm (1.5915 inch) Maximum

Run Out

Surface Texture (Ra)

Main 1: N/A

0.25 µm (9.842520 µinch)

Main 2: 0.08

0.25 µm (9.842520 µinch)

Main 3:

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

0.15 4

39.34 mm (1.549 inch) Maximum

5

44.22 mm (1.741 inch) to 44.15 mm (1.738 inch)

6

34.17 mm (1.345 inch) Minimum

7

133.27 mm (5.247 inch) Minimum

Minimum web Thickness Over Collar Face:

44.60 mm (1.756 inch) to 44.53 mm (1.753 inch)

N/A

Main 5: N/A

0.30 µm (0.01181 µinch) Ra (Maximum) N/A

N/A

Number 1, 2, 3, 6, and 7: 18.44

Crankshaft End Float

Main 4: 0.08

N/A

3.0 - 6.0 µm (118.1102 - 236.2205 µinch) Rz 6.5 µm (255.9055 µinch) Rz Max

Number 4 and 5 19.3

Web 8: 22.73

Must be between 0.05 mm (0.00197 inch) and 0.38 mm (0.01496 inch) Thrust Face Regrinding Depth

0.190 mm (0.00748 inch)

Thrust Face Surface Texture (5)

0.30 mm (0.01181 inch) Ra (Maximum)

Steel Crankshafts ( 232-7400 and 3642829)

Crankshaft Balance

100 g.cm, each end

Table 15 C4.4 Crankshaft Re-Manufacture Specifications (Tier 4) ( 376-4076, 455-3694, and 466-4921) Dimension Number

Standard

0.25

0.51

0.76

1

84.00 mm (3.30708 inch) to 83.98 mm (3.30629 inch)

83.75 mm (3.29724 inch) to 83.73 mm (3.29645 inch)

83.49 mm (3.28700 inch) to 83.47 mm (3.28621 inch)

2

68.01 mm (2.67755 inch) to 67.99 mm (2.67677 inch)

67.76 mm (2.66771 inch) to 67.74 mm (2.66692 inch)

67.50 mm (2.65748 inch) to 67.48 mm (2.65669 inch)

0.200

Run Out

Surface Texture (Ra)

83.24 mm (3.27716 inch) to 83.22 mm (3.27637 inch)

Main 1: N/A

0.25 µm (9.842520 µinch)

67.25 mm (2.64763 inch) to 67.23 mm (2.64685 inch)

Main 2: 0.08 mm (0.00315 inch)

0.25 µm (9.842520 µinch)

N/A

3

40.43 mm (1.59173 inch) Maximum

Main 3: 0.15 mm (0.00591 inch)

N/A

4

39.34 mm (1.54882 inch) Maximum

Main 4: 0.08 mm (0.00315 inch)

N/A

Main 5: N/A

0.30 µm (0.01181 µinch) Ra (Maximum)

5

39.835 mm (1.56830 inch) to 39.765 mm (1.56555 inch)

N/A

6

39.39 mm (1.55078 inch) Maximum

7

133.27 mm (5.24684 inch) Minimum

40.235 mm (1.58405 inch) to 40.165 mm (1.58130 inch)

0.25 µm (9.842520 µinch) N/A

N/A

3.0 - 6.0 µm (118.1102 - 236.2205 µinch) Rz 6.5 µm (255.9055 µinch) Rz Max

Minimum web Thickness Over Collar Face: SG Iron Crankshafts

Number 1: 21.37 mm (0.84134 inch)

Number 2, 3, 6, and Number 4 and 7: 5: 19.76 mm 19.51 mm (0.77795 inch) (0.76811 inch)

Web 8: 23.23 mm (0.91457 inch)

Minimum web Thickness Over Collar Face: Steel Crankshafts

Number 1: 21.02 mm (0.82756 inch)

Number 2, 3, 6, and Number 4 and 7: 5: 19.76 mm 19.51 mm (0.77795 inch) (0.76811 inch)

Web 8: 22.45 mm (0.88386 inch)

Crankshaft End Float

Must be between 0.10 mm (0.00394 inch) and 0.41 mm (0.01614 inch)

Thrust Face Regrinding Depth

0.200 mm (0.00787 inch)

Thrust Face Surface Texture (5)

0.30 µm (0.01181 µinch) Ra (Maximum)

Crankshaft Balance

Steel Crankshafts ( 466-4921)

100 g.cm, each end

SGI Crankshafts ( 455-3694)

50 g.cm, each end

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Table 16 Crankshaft Journal Hardness for Tier 2/3 C4.4 Engines (Shore scale) Steel Crankshafts ( 232-7400 and 364-2829)

63 Minimum

SGI Crankshafts (Induction Hardened) ( 359-0715 and 359-0716)

70 Minimum

SGI Crankshafts (Non-Induction Hardened) ( 455-3692 and 455-3693)

37 - 46

Table 17 Crankshaft Journal Hardness for Tier 4 C4.4 Engines (Shore scale) Steel Crankshafts ( 466-4921)

67 Minimum

SGI Crankshafts (Induction Hardened) ( 376-4076)

70 Minimum

SGI Crankshafts (Non-induction Hardened) ( 455-3694)

37 - 46

The hardness of the journals should be checked before any polishing operation. If a journal shows signs of high heat or grinding check the hardness of the journal. A nondestructive Test (NDT) method such as using an Equotip hardness testing tool can be used. Follow the recommendations of the manufacture for the use of the hardness tester. Note: A soft spot may be found on a journal. Check both sides of the soft area if a soft spot occurs. If the hardness of the journal is within the specifications on both sides of the soft area, then the hardness of the journal is acceptable.

NOTICE Do not use a sclerometer to test the hardness of the crankshaft as it may damage the journal surfaces.

Bearings - Mains, Large Ends, and Thrust for C4.4 Oversize bearings are available to support the various crankshaft regrind options listed in "Crankshaft Reusability and Salvage for C4.4 Engines" Three oversize grades are available for the mains and large end shell bearings, 0.250, 0.510, & 0.760 mm. The thrust washer has one oversize grade 0.190 mm (0.00748 inch) (Tier 2/3) and 0.200 mm (0.00787 inch) (Tier 4) available. All oversize bearings are uniquely identified. When servicing the crankshaft locate the fasteners within the bearing caps. If the caps have an interference fit, the caps must be pulled into place by tightening the fasteners (The caps must not be knocked into position as that may dislodge the bearing shell). Replace main bearing cap fasteners after three uses in a fully torqued assembly. Table 18 C4.4 Journal Bearings Crankshaft Part Numbers

232-7400, 359-0715, 359-0716, 364-2829, 455-3692, and 455-3693.(1)

376-4076, 455-3694, and 466-4921.(2)

(1)

C4.4 Non-Emission, Tier 2, and Tier 3 Engines

(2)

C4.4 Tier 4 Engines

Undersize Options

Bearing Part Number

Standard-Size Bearings

353-7423

0.25 mm Undersize

353-7424

0.50 mm Undersize

353-7425

0.75 mm Undersize

353-7426

Standard-Size Bearings

360-3988

0.25 mm Undersize

454-3936

0.50 mm Undersize

454-3940

0.75 mm Undersize

454-3941

Crankshaft Reusability and Salvage for C6.6 and C7.1 Engines The crankshaft main and large end journals can be reground up to three times. The regrinding depths are 0.250 mm (0.0098 inch), 0.510 mm (0.0201 in)& 0.760 mm (0.0299 inch). A journal surface texture of 0.25 µm (9.842520 µinch) Ra (Maximum) must be maintained. The crankshaft thrust faces can be reground once, corresponding to a regrinding depth of 0.200 mm (0.0079 inch). A thrust face surface texture of 0.30 µm (0.01181 µinch) Ra (Maximum) must be maintained. The crankshaft palm can be reground to the minimum of the specified sealing diameter tolerance 133.32 mm (5.249 inch)/ 133.27 mm (5.247 inch). A crankshaft palm surface texture of 3.0 - 6.0 µm (118.1102 - 236.2205 µinch) Rz 6.5 µm (255.9055 µinch) Rz Max must be maintained without spirals. For specifications on reuse and salvage, refer to Illustration 225. Note: After remanufacturing, the main and pin journals are to be free of burrs/damage or indentations.

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Note: A review of the crankshaft journals and radii must be completed post remanufacture for cracks if cracks are present the crankshaft should be disposed of. The crankshaft end float must be between 0.10 mm (0.004 inch) and 0.41 mm (0.016 inch) Specifications for C6.6 and C7.1 Crankshafts

Illustration 225 g06282685

Table 19 Crankshaft Re-Manufacture Dimensions for C6.6 and C7.1 Dimension Number

Standard

0.25

0.51

0.76

Run Out

1

84.00 mm (3.307 inch) to 83.98 mm (3.3063 inch)

83.75 mm (3.297 inch) to 83.73 mm (3.296 inch)

83.49 mm (3.287 inch) to 83.47 mm (3.286 inch)

83.24 mm (3.277 inch) to 83.22 mm (3.276 inch)

Main 1: 0.25 µm N/A (9.842520 µinch)

2

71.99 mm (2.834 inch) to 71.97 mm (2.833 inch)

71.74 mm (2.824 inch) to 71.72 mm (2.824 inch)

71.48 mm (2.814 inch) to 71.46 mm (2.813 inch)

71.23 mm (2.804 inch) to 71.21 mm (2.804 inch)

Main 2: 0.25 µm 0.15 (9.842520 µinch)

0.200

Surface Texture (Ra)

N/A

3

38.038 mm (1.4976 inch) Maximum

Main 3: 0.15

N/A

4

35.25 mm (1.388 inch) Maximum

Main 4: 0.15

N/A

5

32.19 mm (1.267 inch) Maximum

Main 5: 0.15

N/A

Main 6: N/A

0.30 µm (0.01181 µinch) Ra (Maximum)

6

35.235 mm (1.3872 inch) to 35.165 mm (1.3845 inch)

35.635 mm (1.4029 inch) to 35.565 mm (1.4002 inch)

7

133.27 mm (5.247 inch) Minimum

N/A

N/A

N/A

Number 10: 23.61

Number 11: 23.15

Number 12: 27.36

Minimum web Thickness Over Collar Face

Number 1: 25.61

Number 2,4,6,8: 23.36

Number 3,5,7,9: 23.36

Crankshaft End Float

Between 0.1 mm (0.00394 inch) and 0.41 mm (0.01614 inch)

Thrust Face Regrinding Depth

0.200 mm (0.00787 inch)

Thrust Face Surface Texture (6)

0.30 µm (0.01181 µinch) Ra (Maximum)

Crankshaft Balance

Steel - 100 g.cm at each end

Crankshaft Journal Hardness

67 Shore Minimum

Crankshaft Journal Surface Texture

0.25 µm (9.842520 µinch)Ra (Maximum)

The hardness of the journals should be checked before any polishing operation. If a journal shows signs of high heat or grinding check the hardness of the journal. A nondestructive Test (NDT) method such as using an Equotip hardness testing tool can be used. Follow the recommendations of the manufacture for the use of the hardness tester. Note: A soft spot may be found on a journal. Check both sides of the soft area if this occurs. If the hardness of the journal is within the specifications on both sides of the soft area, then the hardness of the journal is acceptable.

NOTICE Do not use a sclerometer to test the hardness of the crankshaft as it may damage the journal surfaces.

Bearings - Mains, Large Ends, and Thrust forC6.6 and C7.1 Oversize bearings are available to support the various crankshaft regrind options listed in "Crankshaft Reusability and Salvage for C6.6 and C7.1 Engines". Three oversize grades are available for the mains and large end shell bearings: 0.250 mm (0.00984 inch), 0.510 mm (0.02008 inch), and 0.760 mm (0.02992 inch). The thrust washer has one oversize grade 0.200 mm (0.0079 inch) available. All oversize bearings are uniquely identified. The reuse of the main bearing cap fasteners at first assembly is allowed up to three times. New fasteners are required should more than four torque attempts be required during first assembly. For prototype build and assembly slave fixings must be used during the parent & fitted bore measurements, final assembly should then be completed with the original as supplied main bearing cap fasteners. If this tightening and reuse process is not followed, a main bearing cap or crankshaft failure may r080crc15 occur. Caterpillar: Confidential Yellow https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&calledp… 84/139

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Shell bearings can be reused provided there is no significant polish/scuffing on the bearing surface and that the bearing can bed retained within the bearing housing (No significant loss in free spread.) Table 20 C6.6 and C7.1 Journal Bearings Undersize Options

Bearing Part Number

Standard-Size Bearings

360-1978(1)

0.25 mm Undersize

454-3745(2)

0.50 mm Undersize

454-3931(3)

0.75 mm Undersize

454-3935(4)

(1)

448-4217 for engine prefixes 881, D8T, and 7L3

(2)

448-4222 for engine prefixes 881, D8T, and 7L3

(3)

448-4220 for engine prefixes 881, D8T, and 7L3

(4)

448-4218 for engine prefixes 881, D8T, and 7L3

Specifications and Measuring Procedures for C7 through C175 Engines NOTICE For all C9 engines, with few exceptions, the wear sleeve will only need replacement at engine overhaul.

C9 engines that require a crankshaft rear seal installation will need a visual inspection of the seal mating surfaces. Inspect the crankshaft mating seal area for grooves, burrs, scratches, poor surface texture, and visual out of roundness. Refer to the "Seal Surface" section for additional guidance. If the crankshaft mating seal area is damaged, then a wear sleeve replacement would be required. Refer to the Disassembly and Assembly manual for further replacement instructions. Note: Lip seals are sensitive to the quality of the mating components. Mating component surfaces should be checked for defects that would compromise sealing. Do not use the seal if defects are found. These defects include burrs, nicks or large scratches, foreign contamination, poor surface texture, or porosity and visual out of roundness. Use care when handling seals. Clean cardboard or plastic separators are recommended to prevent damage during the transportation and storage of texture-mating components. Mating components should be handled in such a way to reduce the risk of damage or contamination.

Total Indicator Runout (TIR) Reuse The maximum "Use Again" TIR for most used crankshafts without straightening or grinding can be found in Table 21. Do not use the crankshaft "as is" if the TIR is more than the specification that is found in Table 21. If a crankshaft is reground, the journals must be in alignment with other surfaces of the crankshaft. The TIR for crankshafts that have been reground is given in Table 21. The crankshaft cannot be used "as is" if the TIR for any of the measurements that follow is more than the specifications that are shown in Table 21. If it is possible, grind the crankshaft to the next standard size and measure the crankshaft again. The measurement for the TIR is not an overall dimension and the measurement is different from the specifications that are shown in Table 22. High displacement crankshafts must have the fillets of the journals shot peened if the journals are ground undersize. Refer to section "Procedure to Shot Peen 3512, 3516, and 3524 High Displacement Crankshafts" for further information on how to shot peen a 3500 crankshaft. Note: The 3406, 3456, C15, and C18 crankshafts have different considerations for checking for straightness.

Illustration 226

g06282936

c7(1) Pilot hub diameter for flywheel (2) Flange face for flywheel (3) Flange for flywheel (4) Main bearing journals (5) Flange or shoulder for pulley, gear, or damper (6) Straight shaft or tapered shaft (7) Flange face for pulley or damper (8) Pilot hub outer diameter for damper

Illustration 227

g06174125

3500 The counterweights are not shown for clarity (1) Pilot hub for flywheel (2) Flange face for flywheel (3) Flange for flywheel (4) Main bearing journals (5) Gear assembly pilot diameter (6) Straight shaft or tapered shaft (7) Flange face for pulley or damper (8) Pilot hub for damper

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

Illustration 228

g06283070

3600 (2) Flange Face for Flywheel (4) Main bearing journals (5) Flange or Shoulder for Pulley, Gear, or Damper (6) Straight Shaft

Illustration 229

g06283135

C175 (1) Pilot Hub Diameter for Flywheel (2) Flange Face for Flywheel (3) Flange for Flywheel (5) Flange or Shoulder for Pulley, Gear, or Damper

Table 21 Measurements of the Maximum TIR Before Straightening the Crankshaft The maximum TIR for the main bearing journals on the used crankshafts and the crankshafts that have been reground is shown in the column named Main Bearing Journals. The other specifications are only for crankshafts that have been reground. It is not necessary to check a used crankshaft for the other dimensions unless the crankshaft has been reground. Crankshafts that have been reground must meet the specifications that follow. If the crankshafts do not meet the specifications, check the method that was used to grind. Part Number

Pilot Hub Diameter for Flywheel (1)

Flange Face for Flywheel (2)

Flange for Flywheel (3)

Main Bearing Journals (4)

Flange or Shoulder for Pulley, Gear, or Damper (5)

Straight Shaft or Tapered Shaft (6)

Flange Face for Pulley or Damper (7)

Pilot Hub Outer Diameter for Damper (8)

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

N/A

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

0.13 mm (0.005 inch)

0.08 mm (0.003 inch)

N/A

N/A

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

N/A

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

N/A

0.08 mm (0.003 in)

0.13 mm (0.005 inch)

N/A

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

0.08 mm (0.003 inch)

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

D334 and 1674 146.0 mm (5.75 inch) 4S-5349 9S-0124 9S-0168 9L-6388

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

D342 146.0 mm (5.75 inch) 4S-7436 6N-2823

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

0.08 mm (0.003 inch)

D343 and 1693 137 mm (5.4 inch) 2P-3839

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

0.08 mm (0.003 inch)

D346 137 mm (5.4 inch) 3N-4439 4S-9763 6N-8324 7S-9746

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.10 mm (0.004 inch)

0.08 mm (0.003 inch)

D348 137 mm (5.4 inch) 1W-7578 3N-4438 6N-7899 9S-2034

0.05 mm (0.002 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.10 mm (0.004 inch)

0.08 mm (0.003 inch)

D349 137 mm (5.4 inch) 3N-4440 6N-8337 8L-9626 8S-9203

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

0.08 mm (0.003 inch)

D353 159.0 mm (6.25 inch) 1M-2800 6H-5841

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

N/A

D379 159.0 mm (6.25 inch) 3N-2957 5L-6286

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

N/A

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D398 159.0 mm (6.25 inch) 3N-3002 5L-6293 4W-7613 4W-7614 4W-7615

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

N/A

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

N/A

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

N/A

0.07 mm (0.003 inch)

0.08 mm (0.003 inch)

N/A

0.07 mm (0.003 inch)

0.03 mm (0.001 inch)

N/A

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

N/A

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

0.06 mm (0.002 inch)

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

0.06 mm (0.002 inch)

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

0.06 mm (0.002 inch)

0.20 mm (0.008 inch)

0.1 mm (0.0039 inch)

0.075 mm (0.0030 inch)

0.20 mm (0.008 inch)

0.1 mm (0.0039 inch)

0.075 mm (0.0030 inch)

0.20 mm (0.008 inch)

0.1 mm (0.0039 inch)

0.075 mm (0.0030 inch)

D399 159.0 mm (6.25 inch) 3N-2958 4W-7718 4W-7719 6L-8246

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

N/A

C7 110.0 mm (4.33 inch) 227-5480 271-5658 489-2731 544-3940

0.06 mm (0.002 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

0.05 mm (0.0020 inch)

C9 112.0 mm (4.41 inch) 115.0 mm (4.53 inch) 261-1544 282-7958

0.06 mm (0.002 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

C10 125.0 mm (4.92 inch) 132-3211 151-2920 169-4187 326-4278

0.06 mm (0.002 inch)

0.03 mm (0.00118 inch)

0.08 mm (0.003 inch)

0.10 mm (0.004 inch)

0.08 mm (0.00315 inch)

C11 130.0 mm (5.12 inch) 221-9362 313-3996

0.06 mm (0.002 inch)

0.03 mm (0.001 inch)

0.08 mm (0.003 inch)

0.10 mm (0.004 inch)

0.08 mm (0.003 inch)

C-12 130.0 mm (5.12 inch) 132-3213 169-4189 243-4815 326-4280

0.06 mm (0.002 inch)

0.03 mm (0.001 inch)

0.08 mm (0.003 inch)

0.10 mm (0.004 inch)

0.08 mm (0.003 inch)

C13 130.0 mm (5.12 inch) 313-3997 361-5594

0.06 mm (0.002 inch)

0.03 mm (0.001 inch)

0.08 mm (0.003 inch)

0.10 mm (0.004 inch)

0.08 mm (0.003 inch)

C-15 and C15(1) 137.0 mm (5.39 inch) 160-1799 221-9360 337-0201 352-1225 361-8230

0.075 mm (0.0030 inch)

0.1 mm (0.0039 inch)

0.20 mm (0.008 inch)

0.18 mm (0.007 inch)

0.05 mm (0.002 inch)

C16 140.0 mm (5.51 inch) 137-5920 155-6632 187-8989

0.075 mm (0.0030 inch)

0.10 mm (0.004 inch)

0.2 mm (0.008 inch)

0.18 mm (0.007 inch)

0.8 mm (0.0315 inch)

C18(1) 145.0 mm (5.71 inch) 189-4918 353-8012 366-2498 468-5119 468-5120 468-5121

0.075 mm (0.0030 inch)

0.10 mm (0.004 inch)

0.2 mm (0.008 inch)

0.18 mm (0.007 inch)

0.8 mm (0.03 inch)

r080crc15 Caterpillar: Confidential Yellow

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C27 137.0 mm (5.39 inch) 225-6053 384-9907

0.075 mm (0.0030 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.8 mm (0.03 inch)

0.20 mm (0.008 inch)

0.05 mm (0.002 inch)

0.075 mm (0.0030 inch)

0.20 mm (0.008 inch)

0.05 mm (0.002 inch)

0.075 mm (0.0030 inch)

0.8 mm (0.03 inch)

0.20 mm (0.008 inch)

0.05 mm (0.002 inch)

0.075 mm (0.0030 inch)

0.5 mm (0.02 inch)

N/A

N/A

N/A

Straight

N/A

N/A

Straight

N/A

N/A

N/A

N/A

N/A

Straight

N/A

N/A

Straight

N/A

N/A

0.07 mm (0.003 inch)

0.08 mm (0.003 inch)

N/A

0.07 mm (0.003 inch)

0.08 mm (0.003 inch)

N/A

0.064 mm (0.0025 inch)

0.05 mm (0.002 inch)

N/A

C30 145.0 mm (5.71 inch) 213-3202 384-9906

0.075 mm (0.0030 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.8 mm (0.03 inch)

C32 145.0 mm (5.71 inch) 224-3252 384-9908

0.075 mm (0.0030 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch) C175

359-0941 356-7064 397-8617

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.0020 inch)

0.13 mm (0.005 inch)

3044 94.0 mm (3.70 inch) 234-4794

N/A

N/A

0.15 mm (0.006 inch)

NA

N/A

3046 94.0 mm (3.70 inch) 107-0992 117-2830

N/A

N/A

N/A

0.15 mm (0.006 inch)

N/A

3054 100.0 mm (3.94 inch) or 103.0 mm (4.06 inch) 4P-9948 139-7018 165-4640 232-7400 225-8841 359-0715 484-8067

N/A

N/A

0.05 mm (0.002 inch)

0.08 mm (0.003 inch) 0.15 mm (0.006 inch)

0.05 mm (0.002 inch)

3064 102.0 mm (4.02 inch) 5I-7844 135-2419

N/A

N/A

N/A

0.020 mm (0.0008 inch)

N/A

3066 102.0 mm (4.02 inch) 125-3005

N/A

N/A

N/A

0.020 mm (0.0008 inch)

N/A

3114 105 mm (4.13 inch) 4W-3989

0.06 mm (0.002 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

3116 105.0 mm (4.13 inch) 3126 110.0 mm (4.33 inch) 4W-3498 105-1725 259-3246 271-5658 489-2731

0.06 mm (0.002 inch)

0.05 mm (0.002 inch)

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

1140, 1145, and 3145 114 mm (4.5 inch) 9L-6264 9L-7604 9L-8127

0.03 mm (0.001 inch)

0.08 mm (0.003 inch)

0.038 mm (0.0015 inch)

0.08 mm (0.003 inch)

0.03 mm (0.001 inch)

1150 and 3150 114.3 mm (4.50 inch) 9L-7603

0.03 mm

0.08 mm

0.038 mm

0.08 mm

0.03 mm (0.001 inch)

0.064 mm

0.05 mm

r080crc15 Caterpillar: Confidential Yellow

N/A

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9L-8128

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

(0.001 inch)

(0.003 inch)

(0.0015 inch)

(0.003 inch)

(0.0025 inch)

(0.002 inch)

0.064 mm (0.0025 inch)

0.05 mm (0.002 inch)

N/A

1160 and 3160 114 mm (4.5 inch) 9L-6266 9L-7605 9L-8142

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.038 mm (0.0015 inch)

0.13 mm (0.005 inch)(2) 0.08 mm (0.003 inch)(3)

0.03 mm (0.001 inch)

3176 125.0 mm (4.92 inch) 122-0721 326-4278

0.06 mm (0.002 inch)

0.03 mm (0.00118 inch)

0.08 mm (0.003 inch)

0.10 mm (0.004 inch)

0.08 mm (0.00315 inch)

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

N/A

116-1081

0.06 mm (0.002 inch)

0.03 mm (0.001 inch)

0.08 mm (0.003 inch)

0.10 mm (0.004 inch)

0.05 mm (0.002 inch)

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

N/A

0.05 mm (0.002 inch)

0.03 mm (0.001 inch)

0.06 mm (0.002 inch)

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

N/A

0.127 mm (0.0050 inch)

0.076 mm (0.0030 inch)

N/A

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

N/A

0.08 mm (0.003 inch)

0.13 mm (0.005 inch)

N/A

3196 130.0 mm (5.12 inch) 326-4280

0.06 mm (0.002 inch)

0.03 mm (0.001 inch)

0.08 mm (0.003 inch)

0.10 mm (0.004 inch)

0.05 mm (0.002 inch)

3204 114 mm (4.5 inch) 1W-0401 1W-9771

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

0.04 mm (0.002 inch)

0.08 mm (0.003 inch)

0.08 mm (0.003 inch)

3208 114 mm (4.5 inch) 9N-6221 9Y-7605

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.076 mm (0.0030 inch)

0.13 mm (0.005 inch)(2) 0.08 mm (0.003 inch)(3)

0.05 mm (0.002 inch)

D330C and 3304 121 mm (4.75 inch) 2P-6214 2W-7960 4N-7692 5Y-1544 6C-3288 337-0872

N/A

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.08 mm (0.003 inch)

D333C, 3306, G3306and 1673C 121.0 mm (4.75 inch) 2P-6219 2W-7458 2Y-4507 4N-7693 4N-7697 4P-9857 5Y-1546 334-8389 344-2603

N/A

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.08 mm (0.003 inch)

3406(1) 137.0 mm (5.39 inch) 1W-7821

0.075 mm (0.0030 inch)

0.03 mm (0.001 inch)

0.20 mm (0.008 inch)

0.18 mm (0.007 inch)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.001 inch)

0.076 mm (0.0030 inch)

4W-0741

0.03 mm (0.001 inch)

0.05 mm (0.002 inch)

0.038 mm (0.0015 inch)

0.13 mm (0.005 inch)(2) 0.08 mm (0.003 inch)(3)

0.03 mm (0.001 inch)

0.064 mm (0.0025 inch)

0.05 mm (0.002 inch)

N/A

7C-4859 117-0457

0.075 mm (0.0030 inch)

0.03 mm (0.001 inch)

0.20 mm (0.008 inch)

0.18 mm (0.007 inch)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.001 inch)

0.076 mm (0.0030 inch)

6I-1453 136-8882 430-2593

0.075 mm (0.0030 inch)

0.03 mm (0.001 inch)

0.20 mm (0.008 inch)

0.18 mm (0.007 inch)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.001 inch)

0.075 mm (0.0030 inch)

101-1717

0.075 mm (0.0030 inch)

0.03 mm (0.001 inch)

0.20 mm (0.008 inch)

0.18 mm (0.007 inch)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.001 inch)

0.075 mm (0.0030 inch)

137-5920

0.075 mm (0.0030 inch)

0.03 mm (0.001 inch)

0.20 mm (0.008 inch)

0.18 mm (0.007 inch)

0.05 mm (0.002 inch)

0.080 mm (0.0031 inch)

0.025 mm 0.075 mm r080crc15 (0.001 inch)Caterpillar: (0.0030 inch) Yellow Confidential

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3408 137.0 mm (5.39 inch)

1W-5009

0.08 mm (0.003 inch)

0.025 mm (0.0010 inch)

0.20 mm (0.008 inch)

0.13 mm (0.005 inch)(2) 0.08 mm (0.003 inch)(3)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.0010 inch)

0.08 mm (0.003 inch)

1W-6209

0.08 mm (0.003 inch)

0.025 mm (0.0010 inch)

0.20 mm (0.008 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.0010 inch)

0.08 mm (0.003 inch)

3412 137.0 mm (5.39 inch) 1W-6213 9Y-5381 261-9647

0.127 mm (0.0050 inch)

0.025 mm (0.0010 inch)

0.20 mm (0.008 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.0010 inch)

0.127 mm (0.0050 inch)

213-3202 384-9906

0.075 mm (0.0030 inch)

0.025 mm (0.0010 inch)

0.20 mm (0.008 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

0.20 mm (0.008 inch)

0.025 mm (0.0010 inch)

0.075 mm (0.0030 inch)

0.20 mm (0.008 inch)

0.1 mm (0.0039 inch)

0.075 mm (0.0030 inch)

0.05 mm (0.002 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

3456 140.0 mm (5.51 inch) 137-5920

0.075 mm (0.0030 inch)

0.10 mm (0.004 inch)

0.2 mm (0.008 inch)

0.18 mm (0.007 inch)

0.8 mm (0.0315 inch)

3508 170.0 mm (6.69 inch) 7E-3912 7E-4899 7W-0210 9Y-3798 152-4994 152-7625 153-3928

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

3512 170.0 mm (6.69 inch) 1W-5001 7E-4897 7W-0214 8N-7105 128-6786 153-6508 161-2512 173-1812 201-4250 322-9879 354-2977 416-8754

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

3512 3524 High Displacement 170.0 mm (6.69 inch) 201-4250 354-2977

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

3516 170.0 mm (6.69 inch) 7E-3916 7E-5165 7W-0218 8N-9700 128-6788 153-6509 448-8940

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

3516 High Displacement 170.0 mm (6.69 inch) 160-5916 172-0916 347-0966 448-8942 448-8943 506-1982 506-1983

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

r080crc15 Caterpillar: Confidential Yellow

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3520 170.0 mm (6.69 inch) 140-1164 245-1336 315-1391 322-9885 351-9210

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 inch)

0.13 mm (0.005 inch)

0.05 mm (0.002 inch)

0.05 mm (0.002 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch.)

0.05 mm (0.002 inch)

N/A

N/A

0.05 mm (0.002 inch)

N/A

N/A

0.05 mm (0.002 inch)

N/A

N/A

0.05 mm (0.002 inch)

N/A

N/A

0.05 mm (0.002 inch)

N/A

N/A

3606 C280-6 280.0 mm (11.02 inch) 7C-7973 159-5216 179-3573 361-8845

N/A

0.05 mm (0.002 inch)

N/A

0.08 mm (0.003 inch)

0.5 mm (0.02 inch)

3608 C280-8 280.0 mm (11.02 inch) 7C-7974 193-5845 361-8847

N/A

0.05 mm (0.002 inch)

N/A

0.08 mm (0.003 inch)

0.5 mm (0.02 inch)

3612 C280-12 280.0 mm (11.02 inch) 7C-7975 191-5424 361-8849 361-8850

N/A

0.05 mm (0.002 inch)

N/A

0.08 mm (0.003 inch)

0.5 mm (0.02 inch)

3616 C280-16 280.0 mm (11.02 inch) 7C-7976 189-2499 361-8851

N/A

0.05 mm (0.002 inch)

N/A

0.08 mm (0.003 inch)

0.5 mm (0.02 inch)

3618 280.0 mm (11.02 inch) 137-0140

N/A

0.05 mm (0.002 inch)

N/A

0.08 mm (0.003 inch)

(1)

Refer to section "Special Considerations for 3406, 3456, C15, and C18 Crankshafts".

(2)

Main Bearing Journals 2 and 4

(3)

Main Bearing Journal 3

0.5 mm (0.02 inch)

Specifications for Straightening a Crankshaft The maximum TIR for straightening most Caterpillar crankshafts is found in Table 22. If the TIR for any of the measurements that follow is more than the specifications shown in Table 22, the crankshaft cannot be straightened. Do not straighten crankshafts which are bent beyond these specifications. The measurement is an overall dimension and the measurement is different from the specifications that are shown in Table 21. Table 22 Specifications for Straightening a Crankshaft This table shows the maximum TIR for straightening most Caterpillar crankshafts. The dimensions must be used for straightening purposes only. Do not straighten crankshafts which are bent beyond these specifications. The measurement is an overall dimension and the measurement is different from the specifications and procedures that are shown in “Procedure to Measure Used Crankshafts for Bend”. Part Number

Center Main Maximum TIR for Straightening a Crankshaft

Fillet Processing Induction Hardened

Shot Peening

D333 and 1673 114 mm (4.5 inch) 9M-2337

1.52 mm (0.060 inch)

All Fillets

-

N/A

None

All Fillets

-

D334 and 1674 9S-0124

1.52 mm (0.060 inch) D336 and 1676 114 mm (4.5 in)

9S-0647

1.52 mm (0.060 inch)

r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

D342 146.0 mm (5.75 inch) 3L-8455

3.05 mm (0.120 inch)

All Fillets

NA

4S-7436 6N-2823

2.54 mm (0.100 inch)

None

None

None

None

D343 and 1693 137 mm (5.4 inch) 2P-3839 7M-9201

2.03 mm (0.080 inch)

D346 137 mm (5.4 inch) (60° V-8) 6N-8324

1.02 mm (0.040 inch)

None

All fillets except the gauge length of the journal

D348 137 mm (5.4 inch) (60° V-12) 1W-7578

2.03 mm (0.080 inch)

N/A

None

D349 137 mm (5.4 inch) (60° V-16) 6N-8337

2.54 mm (0.100 inch)

N/A

None

All Fillets

None

D353 159 mm (6.25 inch) 7L-5468

2.54 mm (0.100 inch)

D379 159.0 mm (6.25 inch) (V-8) 3N-2957

1.52 mm (0.060 inch)

All Fillets

None

D398 159.0 mm (6.25 inch) (V-12) 3N-3001 4W-7613

2.54 mm (0.100 inch)

N/A

None

D399 159.0 mm (6.25 inch) (V-16) 3N-2958

3.05 mm (0.120 in)

All Fillets

N/A

4W-7718

3.05 mm (0.120 inch)

N/A

All except front main bearings and rear main bearings

All Fillets

N/A

C7 110.0 mm (4.33 inch) 227-5480 271-5658 489-2731 544-3940

Do Not Straighten.

C9 112.0 mm (4.41 inch) 115.0 mm (4.53 inch) 261-1544 282-7958

Do Not Straighten.

All Fillets

N/A

C10 125.0 mm (4.92 inch) 132-3210 151-2920 169-4187 326-4278

Do Not Straighten.

All Fillets

N/A

C11 130.0 mm (5.12 inch) 221-9362 313-3996

Do Not Straighten.

All Fillets

N/A

C12 130.0 mm (5.12 inch) 132-3213 169-4189

Do Not Straighten.

All Fillets

N/A r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

243-4815 326-4280 C13 130.0 mm (5.12 inch) 313-3997 361-5594

Do Not Straighten.

All Fillets

N/A

C15 137.0 mm (5.39 inch) 160-1799

1.52 mm (0.060 inch)

All Fillets

N/A

221-9360(1) 337-0201 352-1225 361-8230

Do not Straighten.

All Fillets

N/A

C16 140.0 mm (5.51 inch) 137-5920 155-6632 187-8989

1.52 mm (0.060 inch)

All Fillets

N/A

C18 145.0 mm (5.71 inch) 189-4918 353-8012 366-2498 468-5119 468-5120 468-5121

1.52 mm (0.060 inch)

All Fillets

N/A

C27 137.0 mm (5.39 inch) 225-6053 384-9907

2.03 mm (0.080 inch)

N/A

None

N/A

None

N/A

None

N/A

N/A

N/A

N/A

All Fillets

N/A

C30 145.0 mm (5.71 inch) 213-3202 384-9906

2.03 mm (0.080 inch) C32 145.0 mm (5.71 inch)

224-3252 384-9908

2.03 mm (0.080 inch) 3044 94.0 mm (3.70 inch)

234-4794

0.050 mm (0.0020 inch) 3046 94.0 mm (3.70 inch)

107-0992 117-2830

0.050 mm (0.0020 inch) 3054 100.0 mm (3.94 inch) 103.0 mm (4.06 inch)

4P-9948 139-7018 165-4640 225-8841 232-7400 359-0715 484-8067

1.02 mm (0.040 inch)

3056 100.0 mm (3.94 inch) 103.0 mm (4.06 inch) 100-4034 240-8467

1.02 mm (0.040 inch)

All Fillets 3064

N/A r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

102.0 mm (4.02 inch) 5I-7844 135-2419

0.050 mm (0.0020 inch)

All Fillets

N/A

3066 102.0 mm (4.02 inch) 125-3005

0.050 mm (0.0020 inch)

All Fillets

N/A

3114 105.0 mm (4.13 inch) 4W-3989

Do Not Straighten.

N/A

None

All Fillets

N/A

3116 105.0 mm (4.13 inch) 3126 110.0 mm (4.33 inch) 4W-3498 105-1725 227-5480 259-3246 271-5658 489-2731

Do Not Straighten.

1140, 1145, and 3145 114 mm (4.5 inch) (90° V-8) 9L-6264 9L-7604 9L-8127

1.02 mm (0.040 inch)

N/A

None

1150 and 3150 114 mm (4.5 in) (90° V-8) 9L-7603 9L-8128

1.02 mm (0.040 inch)

N/A

None

1160 and 3160 114 mm (4.5 inch) (90° V-8) 9L-6266 9L-7605 9L-8142

1.02 mm (0.040 inch)

N/A

None

All Fillets

N/A

3176 125.0 mm (4.92 inch) 116-1080 122-0721 326-4278

Do Not Straighten.

3196 130.0 mm (5.12 inch) 326-4280

Do Not Straighten.

All Fillets

N/A

N/A

None

N/A

None

N/A

None

3204 114 mm (4.5 in) 1W-0401 1W-9771

1.02 mm (0.040 inch) 3208 114 mm (4.5 inch)

9N-6221 9Y-7605

1.02 mm (0.040 inch) D330C and 3304 121.0 mm (4.75 inch)

2P-6214 2W-7960 4N-7692 5Y-1544 6C-3288 337-0872

1.02 mm (0.040 inch)

D333C, 1673C, G3306 and 3306 121.0 mm (4.75 inch) 2P-6219 2W-7458 2Y-4507

1.52 mm (0.060 inch)

N/A

None

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

4N-7693 4N-7697 4P-9857 5Y-1546 334-8389 344-2603 3406 137.0 mm (5.39 inch) 156-8536

1.52 mm (0.060 inch)

All Fillets

N/A

1W-7821 6I-1453 7C-4859 101-1717 117-0457 136-8882 430-2593

Do not Straighten.

All Fillets

N/A

3408 137.0 mm (5.39 inch) 1W-5009 1W-6209

1.02 mm (0.040 inch)

N/A

None

All Fillets

None

3412 137.0 mm (5.39 inch) 1W-6213 9Y-5381 261-9647

1.52 mm (0.060 inch)

3456 140.0 mm (5.51 inch) 137-5920

1.52 mm (0.060 inch)

All Fillets

N/A

3508 170.0 mm (6.69 inch) (60° V-8) 7E-3912 7E-4899 7W-0210 9Y-3798 152-4994 152-7625 153-3928

2.03 mm (0.080 inch)

N/A

None

3512 170.0 mm (6.69 inch) (60° V-12) 1W-5001 7E-4897 7W-0214 8N-7105 128-6786 153-6508 161-2512 173-1812 201-4250 322-9879 354-2977 416-8754

2.54 mm (0.100 inch)

All Fillets

None

3512 3524 High Displacement 170.0 mm (6.69 inch) (60° V-12) 201-4250 354-2977

2.54 mm (0.100 inch)

All Fillets

All Fillets

3516 170.0 mm (6.69 inch) (60° V-16) 7E-3916 7E-5165 7W-0218 8N-9700 128-6788 153-6509 448-8940

3.05 mm (0.120 inch)

All Fillets

3516

None

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

High Displacement 170.0 mm (6.69 inch) (60° V-16) 160-5916 172-0916 347-0966 448-8942 448-8943 506-1982 506-1983

3.05 mm (0.120 inch)

All Fillets

All Fillets

3520 170.0 mm (6.69 inch) 140-1164 245-1336 315-1391 322-9885 351-9210

3.05 mm (0.120 inch)

All Fillets

N/A

3606 280.0 mm (11.02 inch) 7C-7973 159-5216 179-3573 361-8845

3.05 mm (0.120 inch)

All Fillets

N/A

3608 280.0 mm (11.02 inch) 7C-7974 193-5845 361-8847

3.05 mm (0.120 inch)

All Fillets

N/A

3612 280.0 mm (11.02 inch) 7C-7975 191-5424 361-8849 361-8850

3.05 mm (0.120 inch)

All Fillets

N/A

3616 280.0 mm (11.02 inch) 7C-7976 189-2499 361-8851

3.05 mm (0.120 inch)

All Fillets

N/A

3618 280.0 mm (11.02 inch) 137-0140 (1)

3.05 mm (0.120 inch)

All Fillets

N/A

ACERT Engine

Crankshaft Measurement Specifications Crankshafts must be measured if salvage machining has been performed on the crankshaft or to verify if salvage machining can be performed on the crankshaft. The only measuring technique that has the potential to damage the crankshaft is the hardness inspection. Crankshafts that show no visible signs of wear on the journals or irregularities on the bearing surfaces should not need inspecting for surface texture, hardness, out of round, diameter, or taper. Specification for Surface Texture The maximum permissible surface roughness for bearing journals is given in Table 23. If the journals are rougher than the specification the journals must be polished. The surface texture of the thrust face must be at least 0.45 µm (18 µinch). Ensure that there are no wear steps on the surface or marks from grinding on the surface. Specification for Out of Round and Diameter This is the diameter of the bearing journal before grinding. The allowable diameter of a rod journal or main journal must not be more than the dimensions that are shown in Table 23. Two rod journals can measure 0.005 mm (0.0002 inch) under the minimum specifications for the diameter that are shown in the table.

Illustration 230

g06174163

Section view of main bearing journal. Measure the journal diameter in several places, as shown.

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

Illustration 231

g03780912

Graphical representation of the 20° zone around the oil hole.

The 3500 crankshaft must measure within a diameter and an out of round specification. Illustration 230 demonstrates some various locations to measure diameter. These measurements verify that the crankshaft is within diameter and out of round tolerance. The minimum allowable diameters of a rod journal or main journal are shown in Table 23. The out of round tolerance has two dimensions, within 20° of the oil hole and everywhere else. Refer to Illustration 231 to help identify the oil hole zone. When measuring within the 20° zone around the oil hole, the diametrical tolerance is 0.0203 mm (0.00080 inch). When measuring outside of that zone, the diametrical tolerance is 0.0152 mm (0.00060 inch). For example, if the average journal diameter measures 160.01 mm (6.30 inch), then all measured points will have to be within 160.0024 mm (6.29929 inch) and 160.0227 mm (6.3001 inch) to meet the roundness specification. Two rod journals can measure 0.005 mm (0.0002 inch) under the minimum diameter specifications that are shown in Table 23. Specification for Taper The taper of a rod journal or main journal must not exceed the dimensions that are found in Table 23.

Illustration 232

g06174240

Measure each journal in several different places to check for taper. The 3508 crankshaft is shown with offset connecting rod journals

Illustration 233

g06174243

Measure each journal in several places to check for taper. 3500 crankshaft with shared connecting rod journals

The taper of a rod journal or main journal must not exceed the dimensions that are found in Table 23. Specification for Wear on the Thrust Face The measurement between the thrust faces must be within the specifications that are found in Table 23. Only D330C, 3304, D333C, and 3306 engines have two thicknesses of thrust bearings that are available. The 7N-9343 Thrust Plate was released for the spacer plate block. This 6.73 mm (0.265 inch) thick thrust plate can be used instead of the thinner plate on earlier models when the thrust faces must be ground to make the crankshaft usable. In all other engines, the thrust faces must be ground very lightly. The faces should be ground approximately between 0.02 mm (0.001 inch) and 0.05 mm (0.002 inch) to clean up damaged surfaces. Refer to the explanation of footnote 3 in Table 23. Thrust faces must have a surface texture of 0.45 µm (18.000 µinch) or less after being polished.

Illustration 234

g06174248

(9) Thrust Face (10) Distance between thrust faces

The measurement between the thrust faces must be within the specifications that are found in Table 23. The thrust faces must be ground lightly. Grind the faces approximately between 0.02 mm (0.001 inch) and 0.05 mm (0.002 inch.) to clean up damaged surfaces. Refer to the explanation of footnote 3 in Table 23. Thrust faces must have a surface texture of 0.45 µm (18.000 µinch) or less after being polished. Specification for Radii of the Fillet for the Journal There are two procedures for checking the radius of the fillet. The preferred method is using the correct size of gauge. However, if the correct gauge is not available, use the "Bracket-Check" method. If the radius does not meet the specifications that are shown in Table 23, do not use the crankshaft again. Note: The dimensions of the radius that are given in Table 23 are before the procedure of shot peening. When possible, measure the fillets before the procedure of shot peening. Refer to section "Procedure to Shot Peen 3512, 3516, and 3524 High Displacement Crankshafts" for more information.

Illustration 235 g06174254 Fillet locations (11) Main journal fillet (12) Rod journal fillet

Procedure to Check the Hardness of the Journal Inspect the hardness of a journal if the journal shows signs of high heat damage and after grinding. Use a Non-Destructive Test (NDT) method such as using an Equotip hardness testing tool. Follow the recommendations of the manufacturer for use of the hardness tester. Note: The hardness of the journals should be checked before any polishing operation. Note: Do not use a sclerometer since this method may damage the crankshaft. The readings must be within the tolerances that are shown in Table 23.

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

Note: At times, a soft area will be found on a journal. If this occurs check both sides of this soft area. If the hardness of the journal is within the specifications on both sides of the soft area, the hardness of the journal is acceptable. On some crankshafts, the rear half of the rear main journal and the far rear fillet can be softer than the specifications that are shown in Table 23. Note: The hardness of the journals is measured by using the Shore scale. Be sure to check the scale of the sclerometer that is used. The 6V-6035 Hardness Tester uses the Rockwell C scale. A document is included with the tester to allow conversion from the Rockwell C scale to the Shore scale. Table 23 Crankshaft Measurement Specifications Out of Round (Diameter)

Part Number

Radius(

Taper Thrust

Main

Rod

Main

Face(1)

Rod

Main D333 and 1673 114 mm (4.5 inch)

9M-2337

88.888 ± 0.020 mm (3.4995 ± 0.0008 inch)

76.188 ± 0.020 mm (2.9995 ± 0.0008 inch)

0.018 mm (0.0007 inch)

0.018 mm (0.0007 inch)

42.863 ± 0.064 mm (1.6875 ± 0.0025 inch)

6.10 ± 0.20 mm (0.240 ± 0.008 inch)

D334 and 1674 121.0 mm (4.75 inch) 4S-5349 9L-6388 9S-0124 9S-0168

88.880 ± 0.020 mm (3.4992 ± 0.0008 inch)

76.180 ± 0.020 mm (2.9995 ± 0.0008 inch)

0.015 mm (0.0006 inch)

0.015 mm (0.0006 inch)

42.863 + 0.140 mm − 0.064 mm (1.6875 + 0.0055 inch − 0.0025 inch)

5.54 ± 0.20 mm (0.218 ± 0.008 inch) 5.74 ± 0.20 mm (0.226 ± 0.008 inch)(4)

D336 and 1676 121.0 mm (4.75 inch) 9S-0647

114.30 ± 0.020 mm (4.500 ± 0.0008 inch)

89.916 ± 0.020 mm (3.5400 ± 0.0008 inch)

0.015 mm (0.0006 inch)

0.030 mm (0.0012 inch)

45.31 ± 0.08 mm (1.784 ± 0.003 inch)

6.10 ± 0.20 mm (0.240 ± 0.008 inch)

D342 137 mm (5.4 inch) 3L-8455

95.220 ± 0.025 mm (3.7488 ± 0.0010 inch)

92.050 ± 0.025 mm (3.6240 ± 0.0010 inch)

0.025 mm (0.0010 inch)

0.033 mm (0.0013 inch)

98.362 ± 0.064 mm (3.8725 ± 0.0025 inch)

7.72 ± 0.20 mm (0.304 ± 0.008 inch)

4S-7436 6N-2823

108.204 ± 0.025 mm (4.2600 ± 0.0010 inch)

92.050 ± 0.025 mm (3.6240 ± 0.0010 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

98.43 ± 0.13 mm (3.875 ± 0.005 inch)

7.52 mm (.296 in) Min(5) 7.72 ± 0.20 mm (0.304 ± 0.008 inch)(6)

D343 and 1693 137 mm (5.4 inch) 2P-3839 7M-9201

114.292 ± 0.020 mm (4.4997 ± 0.0008 inch)

89.908 ± 0.020 mm (3.5397 ± 0.0008 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

53.34 + 0.15 mm − 0.08 mm (2.100 + 0.006 inch − 0.003 in)

5.89 mm (0.232 in) Min 8.38 ± 0.208 mm (0.330 ± 0.008 inch)(16)

D346 137 mm (5.4 inch) 3N-4439 4S-9763 6N-8324 7S-9746

133.342 ± 0.020 mm (5.2497 ± 0.0008 inch)

111.117 ± 0.020 mm (4.3747 ± 0.0008 inch)

0.023 mm (0.0009 inch)

0.018 mm (0.0007 inch)

60.60 + 0.15 mm − 0.08 mm (2.386 + 0.006 in − 0.003 inch)

5.54 ± 0.20 mm (0.218 ± 0.008 inch) 5.74 ± 0.20 mm (0.226 ± 0.008 inch)(4)

D348 137 mm (5.4 inch) 1W-7578 3N-4438 6N-7899 9S-2034

133.342 ± 0.020 mm (5.2497 ± 0.0008 inch)

111.117 ± 0.020 mm (4.3747 ± 0.0008 inch)

0.023 mm (0.0009 inch)

0.018 mm (0.0007 inch)

60.60 + 0.15 mm − 0.08 mm (2.386 + 0.006 inch − 0.003 inch)

5.54 ± 0.20 mm (0.218 ± 0.008 inch) Min 5.74 ± 0.20 mm (0.226 ± 0.008 inch)(16)

D349 137 mm (5.4 inch) 3N-4440 6N-8337 6N-8337 8L-9626 8S-9203

133.342 ± 0.020 mm (5.2497 ± 0.0008 inch)

111.117 ± 0.020 mm (4.3747 ± 0.0008 inch)

0.023 mm (0.0009 inch)

0.018 mm (0.0007 inch)

60.60 + 0.15 mm − 0.08 mm (2.386 + 0.006 in − 0.003 inch)

D353 159.0 mm (6.25 inch)

5.54 ± 0.20 mm (0.218 ± 0.008 inch) Min(7) 5.74 ± 0.20 mm (0.226 ± 0.008 inch)(8) r080crc15 Caterpillar: Confidential Yellow

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1M-2800 6H-5841 7L-5468

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

117.450 ± 0.025 mm (4.6240 ± 0.0010 inch)

104.750 ± 0.025 mm (4.1240 ± 0.0010 inch)

0.023 mm (0.0009 inch)

0.018 mm (0.0007 inch)

93.612 ± 0.064 mm (3.6855 ± 0.0025 inch)

8.28 mm (0.326 in) Min(9) 8.48 ± 0.20 mm (0.334 ± 0.008 inch)(10)

D379 159.0 mm (6.25 inch) 10.13 mm (0.399 inch) 3N-2957 5L-6286

146.030 ± 0.025 mm (5.7492 ± 0.0010 inch)

126.980 ± 0.025 mm (4.9992 ± 0.0010 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

76.200 ± 0.064 mm (3.0000 ± 0.0025 inch)

Min(15) 10.31 ± 0.1812 mm (0.406 ± 0.007 inch)(11)

D398 159.0 mm (6.25 inch) 3N-3002 4W-7614 4W-7615

146.030 ± 0.025 mm (5.7492 ± .0010 inch)

126.980 ± 0.025 mm (4.999 ± 0.0010 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

76.12 + 0.018 mm − 0.008 mm (3.000 + 0.0007 inch − 0.0003 inch)

10.13 mm (0.399 in) Min(15) 10.31 ± 0.18 mm (0.4059 ± 0.007 inch)(9)

4W-7613

146.030 ± 0.025 mm (5.7492 ± .0010 inch)

109.847 ± 0.025 mm (4.3247 ± 0.0010 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

76.12 + 0.018 mm − 0.008 mm (3.000 + 0.0007 inch − 0.0003 inch)

10.13 mm (0.399 in) Min(15) 10.31 ± 0.18 mm (0.4059 ± 0.007 inch)(9)

D399 159.0 mm (6.25 inch) 3N-2958 4W-7718 4W-7719 6L-8246

146.030 ± 0.025 mm (5.7492 ± .0010 inch)

109.847 ± 0.025 mm (4.3247 ± 0.0010 inch)

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

76.12 + 0.018 mm − 0.008 mm (3.000 + 0.0007 inch − 0.0003 inch)

10.13 mm (0.399 inch) Min(15) 10.31 ± 0.18 mm (0.406 ± 0.007 inch)(9)

C7 110.0 mm (4.33 inch) 227-5480 271-5658 489-2731 544-3940

90.00 ± 0.02 mm (3.543 ± 0.001 inch)

70.00 ± 0.02 mm (2.756 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

38.00 + 0.13 mm − 0.05 mm (1.496 + 0.051 in − 0.002 inch)

2.5 ± 0.2 mm (0.098 ± 0.008 inch)

C9 112.0 mm (4.41 inch) 261-1544 282-7958

104.00 ± 0.02 mm (4.095 ± 0.001 inch)

80.00 ± 0.020 mm (3.150 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

38.00 + 0.13 mm − 0.05 mm (1.496 + 0.051 in − 0.002 inch)

2.5 ± 0.2 mm (0.098 ± 0.007 inch)

C10 125.0 mm (4.92 inch) 132-3211 151-2920 169-4187 326-4278

108.00 ± 0.020 mm (4.252 ± 0.0008 inch)

82.00 ± 0.020 mm (3.228 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

44.00 ± 0.10 mm (1.732 ± 0.004 inch)

2.80 mm (0.110 inch) Min

C11 130.0 mm (5.12 inch) 221-9362 313-3996

108.000 ± 0.020 mm (4.2520 ± 0.0008 inch)

89.000 ± 0.02 mm (3.5039 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

44.00 ± 0.10 mm (1.732 ± 0.004 inch)

3.0 ± 0.2 mm (0.12 ± 0.008 inch)

C12 125.0 mm (4.92 inch) 132-3213 169-4189 243-4815 326-4280

108.00 ± 0.02 mm (4.252 ± 0.001 inch)

89.00 ± 0.020 mm (3.504 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

44.00 ± 0.10 mm (1.732 ± 0.004 inch)

3.0 ± 0.2 mm (0.12 ± 0.008 inch)

C13 130.0 mm (5.12 inch) 313-3997 313-5594

108.000 ± 0.020 mm (4.2520 ± 0.0008 inch)

89.000 ± 0.02 mm (3.5039 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

44.00 ± 0.10 mm (1.732 ± 0.004 inch)

3.0 ± 0.2 mm (0.12 ± 0.008 inch)

C15 (ACERT) 137.0 mm (5.39 inch) 221-9360 337-0201 352-1225 361-8230

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.00 ± 0.02 mm (3.819 ± 0.001 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

48.140 ± 0.100 mm (1.895 ± 0.0039 inch)

2.54 ± 0.20 mm (0.100 ± 0.008 inch) r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

C-15 137.0 mm (5.39 inch) C16 140.0 mm (5.51 inch) 137-5920 155-6632 160-1799 187-8989

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

90.00 ± 0.020 mm (3.543 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.140 ± 0.100 mm (1.8953 ± 0.0039 inch)

2.54 ± 0.2 mm (0.100 ± 0.008 inch)

C18 145.0 mm (5.71 inch) 189-4918 353-8012 366-2498 468-5119 468-5120 468-5121

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.00 ± 0.020 mm (3.8189 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.140 ± 0.100 mm (1.8953 ± 0.0039 inch)

2.54 ± 0.2 mm (0.100 ± 0.008 inch)

C27 137.0 mm (5.39 inch) 225-6053 384-9907

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.140 ± 0.100 mm (1.8953 ± 0.0039 inch)

2.54 ± 0.2 mm (0.100 ± 0.008 inch)

C30 145.0 mm (5.71 inch) 213-3202 384-9906

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.140 ± 0.100 mm (1.8953 ± 0.0039 inch)

2.54 ± 0.2 mm (0.100 ± 0.008 inch)

C32 145.0 mm (5.71 inch) 224-3252 384-9908

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.140 ± 0.100 mm (1.8953 ± 0.0039 inch)

2.54 ± 0.2 mm (0.100 ± 0.008 inch)

C175 359-0941 C175-20 Type II

200.0 ± 0.025 mm (7.87400 ± 0.00098 inch)

142 ± 0.025 mm (5.5905 ± 0.00098 inch)

0.03 mm 0.0012 inch

0.03 mm 0.0012 inch

68 ± 0.1 mm (2.677 ± 0.04 inch)

6 ± 0.25 mm (0.24 ± 0.0098 inch)

(

356-7064 C175-16 Type II

200.0 ± 0.025 mm (7.87400 ± 0.00098 inch)

142 ± 0.025 mm (5.5905 ± 0.00098 inch)

0.03 mm 0.0012 inch

0.03 mm 0.0012 inch

68 ± 0.1 mm (2.677 ± 0.04 inch)

6 ± 0.25 mm (0.24 ± 0.0098 inch)

(

397-8617(12) C175-16 Type II

200.0 ± 0.025 mm (7.87400 ± 0.00098 inch)

142 ± 0.025 mm (5.5905 ± 0.00098 inch)

0.03 mm 0.0012 inch

0.03 mm 0.0012 inch

68 ± 0.1 mm (2.677 ± 0.04 inch)

6 ± 0.25 mm (0.24 ± 0.0098 inch)

(

3.00 mm (0.118 inch)

3

3.00 mm (0.118 inch)

3

3044 94.0 mm (3.70 inch) 234-4794

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

31.019 ± .019 mm (1.2212 ± 0.0007 inch) 3046 94.0 mm (3.70 inch)

107-0992 117-2830

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

31.019 ± .019 mm (1.2212 ± 0.0007 inch) 3054 100.0 mm (3.94 inch) 103.0 mm (4.06 inch)

4P-9948 139-7018 165-4640 225-8841 232-7400 359-0715 484-8067

76.17 ± 0.010 mm (2.999 ± 0.0004 inch)

63.48 ± 0.010 mm (2.499 ± 0.0004 inch)

N/A

N/A

44.18 ± 0.04 mm (1.739 ± 0.002 inch)

3.82 ± 0.14 mm (0.150 ± 0.006 inch)

3056 100.0 mm (3.94 inch) 103.0 mm (4.06 inch) 100-4035 240-8467(13)

76.17 ± 0.010 mm (2.999 ± 0.0004 inch)

63.48 ± 0.010 mm (2.499 ± 0.0004 inch)

N/A

N/A

44.18 ± 0.04 mm (1.739 ± 0.002 inch) 3064 102.0 mm (4.02 inch)

3.82 ± 0.14 mm (0.150 ± 0.006 inch) r080crc15 Caterpillar: Confidential Yellow

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5I-7844 135-2419

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

33.019 ± .019 mm (1.3000 ± 0.0007 inch)

3.00 mm (0.118 inch)

3

3.00 mm (0.118 inch)

3

2.5 ± 0.2 mm (0.10 ± 0.008 inch)

2

3066 102.0 mm (4.02 inch) 125-3005

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

0.030 mm (0.0012 inch)

33.019 ± .019 mm (1.3000 ± 0.0007 inch) 3114 105.0 mm (4.13 inch)

4W-3989

90.00 ± 0.020 mm (3.543 ± 0.0008 inch)

70.00 ± 0.020 mm (2.756 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

38.00 mm + 0.10 mm − 0.05 mm (1.496 + 0.004 inch − 0.002 inch) 3116 105.0 mm (4.13 inch) 3126 110.0 mm (4.33 inch)

4W-3498

90.00 ± 0.020 mm (3.543 ± 0.0008 inch)

70.00 ± 0.020 mm (2.756 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

38.00 + 0.10 mm − 0.05 mm (1.496 + 0.004 inch − 0.002 inch)

2.5 ± 0.2 mm (0.10 ± 0.008 inch)

105-1725 227-5480 259-3246

90.00 ± 0.020 mm (3.543 ± 0.0008 inch)

70.00 ± 0.020 mm (2.756 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

38.00 + 0.10 mm − 0.05 mm (1.496 + 0.004 inch − 0.002 inch)

2.5 ± 0.2 mm (0.10 ± 0.008 inch)

271-5658 489-2731

90.00 ± 0.020 mm (3.543 ± 0.0008 inch)

70.00 ± 0.020 mm (2.756 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

38.00 + 0.10 mm − 0.05 mm (1.496 + 0.004 inch − 0.002 inch)

2.5 ± 0.2 mm (0.10 ± 0.008 inch)

1140, 1145 and 3145 114 mm (4.5 inch) 9L-6264 9L-7604 9L-8127

88.888 ± 0.013 mm (3.4995 ± 0.0005 inch)

69.840 ± 0.015 mm (2.7496 ± 0.0006 inch)

0.010 mm (0.0004 inch)

0.018 mm (0.0007 inch)

31.95 ± 0.05 mm (1.258 ± 0.002 inch)

2.49 ± 0.2 mm (0.098 ± 0.008 inch)

1150 and 3150 114 mm (4.5 inch) 9L-6265 9L-7603 9L-8128

88.888 ± 0.013 mm (3.4995 ± 0.0005 inch)

69.840 ± 0.015 mm (2.7496 ± 0.0006 inch)

0.010 mm (0.0004 inch)

0.018 mm (0.0007 inch)

31.95 ± 0.05 mm (1.258 ± 0.002 inch)

2.49 ± 0.2 mm (0.098 ± 0.008 inch)

1160 and 3160 114 mm (4.5 inch) 9L-6266 9L-7605 9L-8142

88.888 ± 0.013 mm (3.4995 ± 0.0005 inch)

69.840 ± 0.015 mm (2.7496 ± 0.0006 inch)

0.010 mm (0.0004 inch)

0.018 mm (0.0007 inch)

31.95 ± 0.05 mm (1.258 ± 0.002 inch)

2.49 ± 0.2 mm (0.098 ± 0.008 inch)

3176 125.0 mm (4.92 inch) 122-0721 326-4278

100.00 ± 0.020 mm (3.937 ± 0.0008 inch)

82.00 ± 0.020 mm (3.228 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

44.00 ± 0.10 mm (1.732 ± 0.004 inch)

3.0 ± 0.2 mm (0.12 ± 0.008 inch)

116-1081 151-2920 169-4187

108.00 ± 0.020 mm (4.252 ± 0.0008 inch)

82.00 ± 0.020 mm (3.228 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

44.00 ± 0.10 mm (1.732 ± 0.004 inch)

3.0 ± 0.2 mm (0.12 ± 0.008 inch)

3196 125.0 mm (4.92 inch) 169-4189 326-4280

108.00 ± 0.02 mm (4.252 ± 0.001 inch)

89.00 ± 0.020 mm (3.504 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

44.00 ± 0.10 mm (1.732 ± 0.004 inch)

3.0 ± 0.2 mm (0.12 ± 0.008 inch)

3204 114 mm (4.5 inch) 1W-0401(14) 1W-9771

88.880 ± 0.020 mm (3.4992 ± 0.0008 inch)

69.842 ± 0.020 mm (2.7497 ± 0.0006 inch)

0.0127 mm (0.0005 inch)

0.015 mm (0.0006 inch)

37.084 ± 0.064 mm (1.4600 ± 0.0025 inch)

2.54 ± 0.20 mm (0.100 ± 0.008 inch)

3208 114 mm (4.5 inch) 9Y-7605 9N-6221

88.887 ± 0.015 mm (3.4995 ± 0.0006 inch)

69.840 ± 0.015 mm (2.7496 ± 0.0008 inch)

0.010 mm (0.0004 inch)

0.018 mm (0.0007 inch)

31.953 + 0.102 mm − 0.051 mm (1.2580 + 0.0040 inch − 0.0020 inch)

2.54 ± 0.20 mm (0.100 ± 0.008 inch)

9L-6266

88.887 ± 0.013 mm (3.4995 ± 0.0005 inch)

69.840 ± 0.015 mm (2.7496 ± 0.0008 inch)

0.010 mm (0.0004 inch)

0.018 mm (0.0007 inch)

31.95 ± 0.05 mm (1.258 ± 0.002 inch)

2.49 ± 0.2 mm (0.098 ± 0.008 inch)

D330C and 3304 121.0 mm (4.75 inch) 2P-6214 2W-7960

88.880 ± 0.020 mm (3.4992 ± 0.0008 inch)

76.180 ± 0.020 mm (2.9992 ± 0.0008 inch)

0.015 mm (0.0006 inch)

0.013 mm (0.0005 inch)

r080crc15 40.475 + 0.140 mm − 0.064 mm 5.54 mm (0.218 in)(15) Caterpillar: Confidential Yellow (1.5935 + 0.0055 inch − 0.0025 inch) Min

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

5Y-1544 6C-3288 337-0872 4N-7692

5.74 ± 0.20 mm (0.226 ± 0.008 inch)(16) 88.880 ± 0.020 mm (3.4992 ± 0.0008 inch)

76.180 ± 0.020 mm (2.9992 ± 0.0008 inch)

0.015 mm (0.0006 inch)

0.015 mm (0.0006 inch)

40.475 + 0.140 mm − 0.064 mm (1.5935 + 0.0055 inch − 0.0025 inch)

4.74 ± 0.20 mm (0.1866 ± 0.008 inch)

(

D333C, 1673C and 3306 114 mm (4.5 inch) 2P-6219 2Y-4507 4N-7693 4N-7697 5Y-1546

88.880 ± 0.020 mm (3.4992 ± 0.0008 inch)

76.180 ± 0.020 mm (2.9992 ± 0.0008 inch)

0.015 mm (0.0006 inch)

0.020 mm (0.0008 inch)

40.475 + 0.140 mm − 0.060 mm (1.5935 + 0.0055 inch − 0.0024 inch)

5.74 ± 0.20 mm (0.226 ± 0.008 inch)

2W-7458 4P-9857 334-8389 344-2603

88.880 ± 0.020 mm (3.4992 ± 0.0008 inch)

76.180 ± 0.020 mm (2.9992 ± 0.0008 inch)

0.015 mm (0.0006 inch)

0.020 mm (0.0008 inch)

40.475 + 0.140 mm − 0.064 mm (1.5935 + 0.0055 inch − 0.0025 inch)

5.74 ± 0.20 mm (0.226 ± 0.008 inch)

3406 137.0 mm (5.39 inch) 101-1717

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

88.00 ± 0.020 mm (3.46 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.14 ± 0.10 mm (1.895 ± 0.004 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

160-1799

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

90.00 ± 0.020 mm (3.543 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.140 ± 0.100 mm (1.8953 ± 0.0039 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

7C-4859 117-0457

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

90.000 ± 0.020 mm (3.5433 ± 0.0008 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

48.140 ± 0.100 mm (1.895 ± 0.0039 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

1W-7821

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 mm (3.8200 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

48.140 ± 0.100 mm (1.895 ± 0.0039 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

137-5920

120.650 ± 0.020 mm (4.7500 ± 0.0008 in)

90.000 ± 0.020 mm (3.5433 ± 0.0008 in)

0.008 mm (0.0003 in)

0.008 mm (0.0003 in)

48.140 ± 0.100 mm (1.895 ± 0.0039 in)

2.36 ± 0.2 mm (0.093 ± 0.008 in)

3408 137.0 mm (5.39 inch) 1W-6209

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

48.11 + 0.16 mm − 0.08 mm (1.894 + 0.006 inch − 0.003 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

1W-5009

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

48.11 + 0.16 mm − 0.08 mm (1.894 + 0.006 inch − 0.003 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

3412 137.0 mm (5.39 inch) 1W-6213 9Y-5381 261-9647

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

48.11 + 0.16 mm − 0.08 mm (1.894 + 0.006 inch − 0.003 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

213-3202 384-9906

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)

0.020 mm (0.0008 inch)

0.020 mm (0.0008 inch)

48.11 + 0.16 mm − 0.08 mm (1.894 + 0.006 inch − 0.003 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

3456 140.0 mm (5.51 inch) 137-5920 155-6632 187-8989

120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)

90.00 ± 0.020 mm (3.543 ± 0.0008 inch)

0.008 mm (0.0003 inch)

0.008 mm (0.0003 inch)

48.140 ± 0.100 mm (1.8953 ± 0.0039 inch)

2.36 ± 0.2 mm (0.093 ± 0.008 inch)

3508 170.0 mm (6.69 inch) 7E-3912 7E-4899 7W-0210 9Y-3798 152-4994 152-7625 153-3928

160.000 ± 0.025 mm (6.2992 ± 0.0010 inch)

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

72.00 ± 0.10 mm (2.835 ± 0.004 inch)

7.00 ± 0.25 mm (0.276 ± 0.010 inch)

3512 170.0 mm (6.69 inch) 1W-5001 7E-4897 7W-0214 8N-7105 128-6786 153-6508 161-2512

160.000 ± 0.025 mm (6.2992 ± 0.0010 inch)

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

72.00 ± 0.10 mm (2.835 ± 0.004 inch)

7.00 ± 0.25 mm (0.276 ± 0.010 inch)

r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

173-1812 201-4250 322-9879 354-2977 416-8754 3512 3524 High Displacement 170.0 mm (6.69 inch) 201-4250 354-2977

160.00 ± .025 mm (6.299 ± 0.001 inch)

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch.)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

72.00 ± 0.10 mm (2.835 ± 0.004 inch)

7.00 ± 0.25 mm (0.276 ± 0.010 inch)

3516 170.0 mm (6.69 inch) 7E-3916 7E-5165 7W-0218 8N-9700 128-6788 153-6509 448-8940

160.00 ± .025 mm (6.299 ± 0.001 inch)

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

72.00 ± 0.10 mm (2.835 ± 0.004 inch)

7.00 ± 0.25 mm (0.276 ± 0.010 inch)

3516 High Displacement 170.0 mm (6.69 inch) 160-5916 172-0916 347-0966 448-8942 448-8943 506-1982 506-1983

160.00 ± .025 mm (6.299 ± 0.001 inch)

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

72.00 ± 0.10 mm (2.835 ± 0.004 inch)

7.00 ± 0.25 mm (0.276 ± 0.010 inch)

3520 170.0 mm (6.69 inch) 140-1164 245-1336 315-1391 322-9885 351-9210

160.00 ± .025 mm (6.299 ± 0.001 inch)

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

72.00 ± 0.10 mm (2.835 ± 0.004 inch)

7.00 ± 0.25 mm (0.276 ± 0.010 inch)

3606 C280-6 280.0 mm (11.02 inch) 7C-7973 159-5216 179-3573 361-8845

250.000 ± 0.025 mm (9.8425 ± 0.0010 inch)

216.000 ± 0.025 mm (8.5040 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

120.00 ± 0.05 mm (4.724 ± 0.002 inch)

13.5 ± 0.5 mm (0.53 ± 0.02 inch)

3608 C280-8 280.0 mm (11.02 inch) 7C-7974 193-5845 361-8847

250.000 ± 0.025 mm (9.8425 ± 0.0010 inch)

216.000 ± 0.025 mm (8.5040 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

120.00 ± 0.05 mm (4.724 ± 0.002 inch)

13.5 ± 0.5 mm (0.53 ± 0.02 inch)

3612 C280-12 280.0 mm (11.02 inch) 7C-7975 191-5424 361-8849 361-8850

250.000 ± 0.025 mm (9.8425 ± 0.0010 inch)

216.000 ± 0.025 mm (8.5040 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

120.00 ± 0.05 mm (4.724 ± 0.002 inch)

13.5 ± 0.5 mm (0.53 ± 0.02 inch)

3616 C280-16 280.0 mm (11.02 inch) 7C-7976 189-2499 361-8851

250.000 ± 0.025 mm (9.8425 ± 0.0010 inch)

216.000 ± 0.025 mm (8.5040 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

120.00 ± 0.05 mm (4.724 ± 0.002 inch)

13.5 ± 0.5 mm (0.53 ± 0.02 inch)

3618 280.0 mm (11.02 inch) 137-0140

250.000 ± 0.025 mm (9.8425 ± 0.0010 inch)

216.000 ± 0.025 mm (8.5040 ± 0.0010 inch)

0.03 mm (0.001 inch)

0.03 mm (0.001 inch)

120.00 ± 0.05 mm (4.724 ± 0.002 inch)

r080crc15 13.5 ± 0.5 mm Caterpillar: (0.53 Confidential ± 0.02 inch)Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

(1)

The maximum width of the thrust face can be up to 0.08 mm (0.003 inch) more than the dimension that is shown if the play at the end of the crankshaft is still permissible according to the specifications in the Service Manual after assembly.

(2)

“Dimensions” for the radius give only the correct radius gauges. The dimensions are not the size for dressing the grinding wheel.

(3)

A sclerometer should not be used on any remanufactured crankshaft that has gone through Melonited Heat Treat (MHT) because the crankshaft will be damaged. The crankshaft will have "Melonited Heat Treat" next to the part number.

(4)

center only

(5)

Journals 1 through 3 and 5 through 6

(6)

High Displacement Applications

(7)

Journals 1 through 4 and 6 through 9

(8)

Journal 5

(9)

Intermediate main Journals 2 through 3 and 5 through 6

(10)

Front, center, and rear main Journals 1, 4, 7

(11)

Front and rear main Journals only

(12)

397-8261 has a unique rear flange and shot peened fillets.

(13)

Crankshaft 240-8467 is hardened after machining.

(14)

Refer to the “Special Checking Procedures for Specific Crankshafts" section for additional information”.

(15)

center and intermediate main Journals only

(16)

only the rear

Grinding Specifications for Crankshafts The following information explains some of the items in the table. Width This is the size of the wheel (sidewall to sidewall) that is necessary to grind in a single movement. Do not use any wheel that is wider than this dimension without dressing the wheel to be narrower. Refer to Table 23 for the measurements of the width of main journals at the location of the thrust bearing. Main Number This column shows the numbers of the main journals which have a "width" dimension that is different from the "thrust face" journal at the location of the thrust bearing. These dimensions will be narrower than the main journal with the thrust bearings. Undersize Bearing These dimensions give the optional sizes of undersize bearings that are available for the crankshafts. Check the parts book and check the NPR to ensure that the part numbers are available before beginning to grind. Subtract the "undersize" dimension from the dimension in the "diameter" column in Table 23 to get the size of the journal. Note: The specifications for grinding a crankshaft with a "0R" part number are not included in this publication because "0R" crankshafts have already been ground.

Illustration 236

g06174275

Main Bearing Width (13)

r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

Illustration 237

g06174279

Thrust Bearing Width (14)

Illustration 238

g06174281

Connecting Rod Bearing Width (15) with offset journals

Illustration 239

g06174284

Typical example of a 3500 crankshaft with shared connecting rod journals Table 24 Grinding Specifications for Caterpillar Crankshafts Part Number

Stroke

Main Journals Width Main No.(1)

Connecting Rod Journals Width(2)

Undersize Bearing

D334 and 1674 121.0 mm (4.75 inch)

9S-0124

152.4 mm (6.00 inch)

43.485 mm (1.7120 in) max

1 through 3, 5 through 7

42.80 mm (1.685 inch) to 43.00 mm (1.693 inch)

4

47.689 ± 0.140 mm (1.8775 ± 0.0055 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

D342 146.0 mm (5.75 inch) 4M-0447

6N-2823 4S-7436

203.2 mm (8.00 inch)

203.2 mm (8.00 inch)

63.50 ± 0.127 mm (2.500 ± 0.0050 inch)

2,3,5,6

100.630 mm (3.962 inch) Max

Rear Only

98.42 ± 0.13 mm (3.875 ± 0.005 inch)

4

65.710 mm (2.5870 inch) max

2,3,5,6

80.899 ± 0.064 mm (3.1850 ± 0.0025 inch)

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

66.624 ± 0.127 mm (2.6230 ± 0.0050 inch)

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

D343 and 1693 137 mm (5.4 inch)

2P-3839

165.1 mm (6.50 inch)

53.26 mm (2.097 inch) to 53.49 mm (2.106 inch)

Rear Only

50.216 mm (1.9770 inch) max

2 through 6

54.966 ± 0.076 mm (2.1640 ± 0.0030 inch)

D346 137 mm (5.4 inch) (90° V-8)

2S-3686

165.1 mm (6.50 inch)

62.509 mm (2.4610 inch) max

1,2,4,5

60.76 mm (2.392 inch) to 60.53 mm (2.383 inch)

3

85.801 ± 0.178 mm (3.3780 ± 0.0070 inch)

D348 137 mm (5.4 inch)

1W-7578

165.1 mm (6.50 inch)

62.509 mm (2.4610 inch) max

1 through 5

60.615 mm (2.386 inch) to 60.52 mm (2.382 inch)

Rear Only

85.801 ± 0.178 mm (3.3780 ± 0.0070 inch)

D349 137 mm (5.4 inch)

6N-8337

165.1 mm (6.50 inch)

62.509 mm (2.4610 inch) max

1 through 4, 6 through 9

60.76 mm (2.392 inch) to 60.53 mm (2.383 inch)

5

85.801 ± 0.178 mm (3.3780 ± 0.0070 inch)

D353 137 mm (5.4 inch)

2P-2800

203.2 mm (8.00 inch)

93.67 ± 0.13 mm (3.688 ± 0.005 inch)

Rear Only

65.71 mm (2.587 inch) max

2,3,5,6

94.54 mm (3.722 inch) Max

Front and Center

66.624 ± 0.076 mm (2.6230 ± 0.0030 inch)

D379 159.0 mm (6.25 inch)

4L-8791

203.2 mm (8.00 inch)

76.38 mm (3.007 inch) to 76.12 mm (2.997 inch)

Front and Rear Only

78.31 mm (3.083 inch) Max

2 through 4

117.412 + 0.178 mm − 0.076 mm (4.6225 + 0.0070 inch − 0.0030 inch)

D398 159.0 mm (6.25 inch)

3N-3001 4W-7613

203.2 mm (8.00 inch)

78.31 mm (3.083 inch) Max

2 through 6

76.38 mm (3.007 inch) to 76.12 mm (2.997 inch)

Front and Rear Only

117.412 ± 0.064 mm (4.6225 ± 0.0025 inch)

r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

D399 159.0 mm (6.25 inch)

6L-8246 4W-7718

203.2 mm (8.00 inch)

76.38 mm (3.007 inch) to 76.12 mm (2.997 inch)

Front and Rear Only

78.308 mm (3.0830 inch) max

2 through 8

117.412 + 0.178 mm − 0.076 mm (4.6225 + 0.0070 inch − 0.0030 inch)

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

N/A

0.250 mm (0.0098 inch)

0.510 mm (0.0201 inch)

N/A

C7 110.0 mm (4.33 inch) 227-5480 271-5658 489-2731 544-3940

127.0 mm (5.00 inch)

37.95 mm (1.494 inch) to 38.13 mm (1.501 inch)

2,3,4,5,7

39.000 + 0.150 mm − 0.075 mm (1.5354 + 0.0059 inch − 0.0030 inch) C9 112.0 mm (4.41 inch)

261-1544 282-7958

149.00 mm (5.866 inch)

37.95 mm (1.494 inch) to 38.13 mm (1.501 inch)

2,3,4,5,7

44.300 + 0.150 mm − 0.075 mm (1.7441 + 0.0059 inch − 0.0030 inch) C10 125.0 mm (4.92 inch)

151-2920

140.00 mm (5.512 inch)

44 ± 0.1 mm (1.73 ± 0.004 inch)

1,2,3,4,5,6,7

52 ± 0.15 mm (2.05 ± 0.006 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

N/A

132-3210 326-4278 169-4187

140.00 mm (5.512 inch)

44 ± 0.1 mm (1.73 ± 0.004 inch)

1,2,3,4,5,6,7

52 ± 0.15 mm (2.05 ± 0.006 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

N/A

52.00 ± 0.15 mm (2.047 ± 0.006 inch)

0.510 mm (0.0201 inch)

0.760 mm (0.0299 inch)

N/A

C11 130.0 mm (5.12 inch) 221-9362 313-3996

140.00 mm (5.512 inch)

44 ± 0.1 mm (1.73 ± 0.004 inch)

1,2,3,4,5,6,7 C12 130.0 mm (5.12 inch)

132-3213

150.00 mm (5.910 inch)

44 ± 0.1 mm (1.73 ± 0.004 inch)

1,2,3,4,5,6,7

52.00 ± 0.15 mm (2.047 ± 0.006 inch)

0.510 mm (0.0201 inch)

0.760 mm (0.0299 inch)

N/A

169-4189 243-4815 326-4280

150.00 mm (5.910 inch)

44 ± 0.1 mm (1.73 ± 0.004 inch)

1,2,3,4,5,6,7

52.00 ± 0.15 mm (2.047 ± 0.006 inch)

0.510 mm (0.0201 inch)

0.760 mm (0.0299 inch)

N/A

52.00 ± 0.15 mm (2.047 ± 0.006 inch)

0.510 mm (0.0201 inch)

0.760 mm (0.0299 inch)

N/A

54.000 ± 0.15 mm (2.1260 ± 0.006 inch)

0.64 mm (0.025 inch)

1.27 mm (0.050 inch)

N/A

54.00 ± 0.15 mm (2.126 ± 0.006 inch)

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

C13 130.0 mm (5.12 inch) 313-3997 361-5594

157.00 mm (6.181 inch)

44 ± 0.1 mm (1.73 ± 0.004 inch)

1,2,3,4,5,6,7 C15 137.0 mm (5.39 inch)

160-1799 221-9360 337-0201 352-1225 361-8230

171.5 mm (6.752 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,4,5,6,7

C16 140.0 mm (5.51 inch) 137-5920 155-6632 187-8989

171.00 mm (6.732 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,4,5,6,7

C18 145.0 mm (5.71 inch)

r080crc15 Caterpillar: Confidential Yellow

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189-4918 353-8012 366-2498 444-3016 468-5119 468-5120 468-5121

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

183.00 mm (7.205 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,4,5,6,7

54.00 ± 0.15 mm (2.126 ± 0.006 inch)

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

C27 137.0 mm (5.39 inch) C30 145.0 mm (5.71 inch) 213-3202 384-9906

152.40 mm (6.000 inch)

48.14 ± 0.1 mm (1.895 ± 0.004 inch)

1,2,3,4,5,6,7

84.582 + 0.180 mm − 0.076 mm (3.3299 + 0.0070 inch − 0.0030 inch)

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

152.40 mm (6.000 inch)

48.14 ± 0.1 mm (1.895 ± 0.004 inch)

1,2,3,4,5,6,7

84.582 + 0.180 mm − 0.076 mm (3.3299 + 0.0070 inch − 0.0030 inch)

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

N/A

N/A

0.635 mm (0.0250 inch)

N/A

N/A

0.250 mm (0.0098 inch)

0.5 mm (0.02 inch)

0.75 mm (0.029 inch)

0.250 mm (0.0098 inch)

0.5 mm (0.02 inch)

0.75 mm (0.029 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

N/A

C32 145.0 mm (5.71 inch) 224-3252 384-9908

162.00 mm (6.378 inch)

48.14 ± 0.1 mm (1.895 ± 0.004 inch)

84.582 + 0.180 mm − 0.076 mm (3.3299 + 0.0070 inch − 0.0030 inch)

1,2,3,4,5,6,7

C175-16 175.0 mm (6.89 inch)

356-7064 397-8261

220.0 mm (8.66140 inch)

68.9 mm (2.71259 inch) Max

1,2,3,4,5,6,7,8,9

68.0 ± 0.1 mm (2.67716 ± 0.00394 inch)

132.0 ± 0.18 mm (5.19684 ± 0.00709 inch)

C175-20 175.0 mm (6.89 inch)

359-0941

220.0 mm (8.66140 inch)

68.9 mm (2.71259 inch) Max

1,2,3,4,5,6,7,8,9,10,11

68.0 ± 0.1 mm (2.67716 ± 0.00394 inch)

132.0 ± 0.18 mm (5.19684 ± 0.00709 inch)

3044 94.0 mm (3.70 inch) 234-4794

94.0 mm (3.70 inch)

31.0 mm (1.22 inch)

5

33.0 mm (1.30 inch) 3046 94.0 mm (3.70 inch)

117-2830 107-0992

94.0 mm (3.70 inch)

31.0 mm (1.22 inch)

7

33.0 mm (1.30 inch) 3114 105.0 mm (4.13 inch)

4W-3989

127.0 mm (5.00 inch)

39.00 mm (1.535 inch) max

2,3,5,

37.95 mm (1.494 inch) to 38.13 mm (1.501 inch)

4

39.00 ± 0.075 mm (1.535 ± 0.0030 inch)

3116 105.0 mm (4.13 inch) 3126 110.0 mm (4.33 inch) 4W-3498 271-5658 105-1725

127.0 mm (5.00 inch)

39.00 mm (1.535 inch) max

2,3,4,5,7

37.95 mm (1.494 inch) to 38.13 mm (1.501 inch)

6

39.00 ± 0.075 mm (1.535 ± 0.0030 inch)

1150 and 3150 114 mm (4.5 inch) 9N-8012

114.3 mm

32.207 ± 0.254 mm

2,3,5

58.776 ± 0.076 mm

0.254 mm

r080crc15 Caterpillar: Confidential Yellow

0.508 mm

N/A

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

(4.50 inch)

(1.2680 ± 0.0100 inch)

(2.3140 ± 0.0030 inch)

(0.0100 inch)

(0.0200 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

N/A

50.00 ± 0.15 mm (1.969 ± 0.006 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

N/A

52.00 ± 0.15 mm (2.047 ± 0.006 inch)

0.510 mm (0.0201 inch)

0.760 mm (0.0299 inch)

N/A

0.510 mm (0.0201 inch)

0.760 mm (0.0299 inch)

N/A

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

N/A

47.689 ± 0.140 mm (1.8775 ± 0.0055 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

47.625 ± 0.064 mm (1.8750 ± 0.0025 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

47.63 ± 0.08 mm (1.8750 ± 0.003 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

47.689 ± 0.140 mm (1.8775 ± 0.0055 inch)

0.254 mm (0.0100 inch)

0.508 mm (0.0200 inch)

0.762 mm (0.0300 inch)

1160 and 3160 114 mm (4.5 inch) 9N-8013

127.0 mm (5.00 inch)

31.95 ± 0.05 mm (1.258 ± 0.002 inch)

58.776 ± 0.076 mm (2.3140 ± 0.0030 inch)

2,3,5

3176 125.0 mm (4.92 inch) 122-0721 326-4278

140.00 mm (5.512 inch)

116-1081

140.00 mm (5.512 inch)

44 ± 0.1 mm (1.73 ± 0.004 inch)

4

47.00 mm (1.850 inch) max

1,2,3,5,6,7

44 ± 0.1 mm (1.73 ± 0.004 inch)

4

47.00 mm (1.850 inch) max

1,2,3,5,6,7

3196 130.0 mm (5.12 inch) 169-4189

150.00 mm (5.910 inch)

43.887 ± 0.1 mm (1.727 ± 0.004 inch)

52.00 ± 0.15 mm (2.047 ± 0.006 inch)

1,2,3,4,5,6,7

3204 114 mm (4.5 inch) 1W-0401

127.0 mm (5.00 inch)

37.084 ± 0.064 mm (1.4600 ± 0.0025 inch)

42.164 ± 0.076 mm (1.6600 ± 0.0030 inch)

1 through 5

3208 114 mm (4.5 inch) 9Y-7605

127.0 mm (5.00 inch)

31.95 ± 0.05 mm (1.258 ± 0.002 inch)

58.776 ± 0.076 mm (2.3140 ± 0.0030 inch)

2,3,5

D330C and 3304 121.0 mm (4.75 inch)

4N-7694

2P-6214

152.4 mm (6.00 inch)

152.4 mm (6.00 inch)

43.485 mm (1.7120 inch) max

2 through 4

40.411 mm (1.590 inch) to 40.615 mm (1.599 inch)

1 (Rear Main Only)

40.894 mm (1.6100 inch) max

2 through 4

D333C, 1673C, and 3306 114 mm (4.5 inch) 2P-6219

4N-7696

152.4 mm (6.00 inch)

152.4 mm (6.00 inch)

40.894 mm (1.6100 inch) max

2 through 6

43.48 mm (1.712 inch) Max

2 through 6

40.411 mm (1.590 inch) to 40.615 mm (1.599 inch)

1 (Rear Main Only)

3406 137.0 mm (5.39 inch) 1W-7821

165.1 mm (6.50 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,4,5,6,7

44.45 + 0.18 mm − 0.08 mm (1.750 + 0.007 inch − 0.003 inch)

0.64 mm (0.025 inch)

1.27 mm (0.050 inch)

N/A

165.1 mm (6.50 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,4,5,6,7

54.000 ± 0.15 mm (2.1260 ± 0.006 inch)

0.64 mm (0.025 inch)

1.27 mm (0.050 inch)

NA

165.1 mm (6.50 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,4,5,6,7

44.45 + 0.18 mm − 0.08 mm (1.750 + 0.007 inch − 0.003 inch)

N/A

N/A

N/A

101-1717 132-1116 156-8536 117-0457

3408 137.0 mm (5.39 inch) 1W-5009

152.4 mm

48.03 mm (1.891 inch)

1,2,4,5

40.56 mm (1.597 inch) min

0.635 mm

r080crc15 Caterpillar: Confidential Yellow

1.27 mm

N/A

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1W-6209

797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

(6.00 inch)

to 48.27 mm (1.900 inch)

(0.0250 inch)

(0.050 inch)

3412 137.0 mm (5.39 inch) 213-3202

152.4 mm (6.00 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,5,6,7

84.582 + 0.180 mm − 0.076 mm (3.3299 + 0.0070 inch − 0.0030 inch)

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

9Y-5381

152.4 mm (6.00 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

1,2,3,5,6,7

44.83 mm (1.765 inch)(3) 44.83 (1.765) 2

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

0.630 mm (0.0248 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

N/A

0.635 mm (0.0250 inch)

1.27 mm (0.050 inch)

3456 140.0 mm (5.51 inch) 132-1116 156-8536

171.00 mm (6.732 inch)

48.03 mm (1.891 inch) to 48.27 mm (1.900 inch)

54.00 ± 0.15 mm (2.126 ± 0.006 inch)

1,2,3,5,6,7

3508 170.0 mm (6.69 inch) 7E-3912 7E-4899 7W-0210 9Y-3798 152-4994 152-7625

190.0 mm (7.48 inch)

73.8 mm (2.906 inch) Max

1, 2, 4, 5

72 ± 0.1 mm (2.835 ± 0.004 inch)

3 Thrust Bearing

136.00 + 0.18 mm − 0.08 mm (5.354 + 0.007 inch − 0.003 inch)

3512 170.0 mm (6.69 inch) 1W-5001 7W-0214 8N-7105 128-6786 161-2512 173-1812 322-9879 416-8754

190.0 mm (7.48 inch)

73.8 mm (2.906 inch) Max

1, 2, 3, 5, 6, 7

72 ± 0.1 mm (2.835 ± 0.004 inch)

4 Thrust Bearing

136.00 ± 0.18 mm (5.354 ± 0.007 inch)

3512 3524 High Displacement 170.0 mm (6.69 inch) 172-0926 201-4250 354-2977

215.0 mm (8.46 inch)

73.8 mm (2.906 inch) Max

1, 2, 3, 5, 6, 7

72 ± 0.1 mm (2.835 ± 0.004 inch)

4 Thrust Bearing

136.00 ± 0.18 mm (5.354 ± 0.007 inch)

3516 170.0 mm (6.69 in.) 7E-3916 7E-5165 7W-0218 8N-9700 128-6788 448-8940

190.0 mm (7.48 inch)

73.8 mm (2.906 inch) Max

1, 2, 3, 4, 6, 7, 8, 9

72 ± 0.1 mm (2.835 ± 0.004 inch)

5 Thrust Bearing

136.00 ± 0.18 mm (5.354 ± 0.007 inch)

3516 High Displacement 170.0 mm (6.69 inch) 160-5916 172-0830 172-0916 347-0966 448-8942 448-8943 506-1982 506-1983

215.0 mm (8.46 inch)

73.8 mm (2.906 inch) Max

1, 2, 3, 4, 6, 7, 8, 9

72 ± 0.1 mm (2.835 ± 0.004 inch)

5 Thrust Bearing

136.00 ± 0.18 mm (5.354 ± 0.007 inch)

G3520 170.0 mm (6.69 inch) 140-1164 245-1336 315-1391

190.0 mm (7.48 inch)

72 ± 0.1 mm (2.835 ± 0.004 inch)

11 Thrust Bearing

73.8 mm

2, 3, 4, 5,

136.00 ± 0.18 mm (5.354 ± 0.007 inch)

N/A

r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

322-9885 351-9210

(2.906 inch) Max

6, 7, 8, 9, 10 3606 C280-6 280.0 mm (11.02 inch)

179-3573 159-5216 7C-7973

300.0 mm (11.81 inch)

120 ± 0.5 mm (4.72 ± 0.020 inch)

2, 3, 4, 5, 6

110.00 ± 0.10 mm (4.331 ± 0.004 inch)

0.25 mm (0.010 inch)

0.50 mm (0.020 inch)

1.00 mm (0.040 inch)

0.25 mm (0.010 inch)

0.50 mm (0.020 inch)

1.00 mm (0.040 inch)

0.25 mm (0.010 inch)

0.50 mm (0.020 inch)

1.00 mm (0.040 inch)

0.25 mm (0.010 inch)

0.50 mm (0.020 inch)

1.00 mm (0.040 inch)

0.25 mm (0.010 inch)

0.50 mm (0.020 inch)

1.00 mm (0.040 inch)

3608 C280-8 280.0 mm (11.02 inch) 325-8461 325-8462 193-5845 7C-7974

300.0 mm (11.81 inch)

120 ± 0.5 mm (4.72 ± 0.020 inch)

2, 3, 4, 5, 6, 7, 8

110.00 ± 0.10 mm (4.331 ± 0.004 inch)

3612 C280-12 280.0 mm (11.02 inch) 191-5424 7C-7975 361-8849

300.0 mm (11.81 inch)

120 ± 0.5 mm (4.72 ± 0.020 inch)

2, 3, 4, 5, 6

194.00 ± 0.10 mm (7.638 ± 0.004 inch)

3616 C280-16 280.0 mm (11.02 inch) 189-2499 134-3043 7C-7976 361-8851

300.0 mm (11.81 inch)

124.00 mm (4.882 inch) max

2, 3, 4, 5, 6, 7, 8

194.00 ± 0.10 mm (7.638 ± 0.004 inch)

3618 280.0 mm (11.02 inch) 137-0140

300.0 mm (11.81 inch)

132 ± 0.5 mm (5.20 ± 0.020 inch)

All Main Journals

208.00 ± 0.10 mm (8.189 ± 0.004 inch)

(1)

For 3500 Engines use Illustrations 236 and 237

(2)

For 3500 Engines use Illustrations 238 and 239

(3)

This is required for grinding the connecting rod journals that are on the 3412 crankshafts by using the “double plunge” method.

Thrust Face Burr On Certain machine C27/C32 engines the connecting rod may create a sharp burr on the thrust face of the crankshaft. The burr is commonly accompanied with radial scoring on the sidewall of the crankshaft and connecting rod. The burr can be removed by using a 6V-2010 Polishing Stone. The journal surface must be protected while using the Polishing Stone on the thrust face. Remove all sharp edges between the arrows shown in Illustration 241, create a 3 mm (0.12 inch) to 5 mm (0.20 inch) radius to remove any sharp edges. Ensure that the stone creates a radius and not a sharp edged chamfer.

Illustration 240

g03815312

Sharp edge formed on a C27/C32 crankshaft.

Illustration 241

g03813082

Example of a burr and radial scoring found on sidewall thrust face.

After removing the burr from the thrust face, inspect the thrust face for surface texture. The C27/C32 rod journal thrust face must have a surface texture Ra under 2.5 µm. r080crc15 Caterpillar: Confidential Yellow

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

If a sharp burr is found on the crankshaft, ensure that the mating connecting rod is inspected for any damage. Refer to Reuse and Salvage Guidelines, SEBF8064, "Reuse and Salvage of Connecting Rods" for further connecting rod inspection guidance.

Oil Hole Dimensions If the oil holes appear to have a sharp edge instead of a rounded edge, then the oil hole edge must be reshaped. If the oil holes are in need of reshaping, then reshape and blend by hand using a portable drill and a 45° multi-flute countersink bit. The radius dimensions given in Illustrations 238 and 239 are for general reference only.

Illustration 242

g06174306

Typical 3500-pin journal oil hole. (A) Blend by hand. (B) Radius roughly 3 mm (0.121 inch) (C) Oil hole outer diameter: 15.25 mm (0.60 inch)

Illustration 243

g06174311

Typical 3500 main journal with through oil hole. (D) 90° (E) Oil hole outer diameter 16.0 ± 1 mm (0.630 ± 0.04 inch)

Oil Plug Installation Installation of the 2W-2288 Plugs should be one of the last assembly procedures performed prior to installation. 1. Inspect all the oil plug mounting threads using a 5/8-18 2B UNF thread gage. If any damaged threads are noticed or the thread gage is unable to insert, then retap the oil hole using a 5/8-18 2B UNF tap. Then try to insert the thread gage again. 2. Use new 2W-2288 Plugs and apply an even layer of Loctite 620 around the entire threads of the new plug. 3. Torque the new plug to 50 ± 7 N·m (37 ± 5 lb ft). Note: Allow the Loctite to cure for 24 hours before use.

Improvements to Crankshafts Table 25 New Crankshaft Assemblies New Crankshaft

Ground

Crankshaft(1)

Upgrade to New Crankshaft(2) 3508

Radius of the Counterweight

Former Crank Assembly

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N/A

0R-7771

N/A

225.00 mm (8.858 inch)

7W-0210

152-4994

0R-6060

0R-3009

225.00 mm (8.858 inch)

7E-3912

153-3928

0R-5952

0R-2539

222.00 mm (8.74 inch)

9Y-3798, 7E-4899

3512 128-6786

0R-6059

0R-3010

225.00 mm (8.858 inch)

7E-3914

153-6508

0R-5436

0R-2540

222.00 mm (8.74 inch)

7W-0214, 7E-4897

172-0926

0R-7767

0R-9739

225.00 mm (8.858 inch)

N/A

3516 448-8940

0R-0788

0R-9737

225.00 mm (8.858 inch)

128-6788

448-8942 506-1982

10R-0576

0R-9738

225.00 mm (8.858 inch)

347-0966

(1)

The crankshaft is ground to 0.635 mm (0.0250 inch) undersize.

(2)

This part number is a ground crankshaft with forged counterweights.

Improvements to 3508 and 3512 Crankshafts The 3508 Engine crankshaft and the 3512 Engine crankshaft have a 225.0 mm (8.86 inch) forged counterweight improving the crankshaft balance. The cylinder block has also been modified to accept this crankshaft improvement. The serial numbers of the engines that are affected by this change are shown in Table 25. Table 26 Effective Engine Part Numbers for Crankshaft Assemblies Model

3508 Engines

3512 Engines

Industrial

95-Y759

49-Y537

Industrial Engine (Low Speed)

68-Z755

65-Z688

Marine

96Y-1028

50-Y864

Marine Engine (Low Speed)

69-Z512

66-Z365

Vehicular

97-Y672

51-Y602

Generator Set

23Z-2819

24Z-2939

Generator Set (Low Speed)

70-Z722

67-Z734

Spark Ignited

N/A

4K-C144

Locomotive

N/A

N/A

1Z-F518

3Y-F408

Generator Set Improvements to 3516 Crankshafts

Illustration 244

g03709912

(H) Traditional Counterweight (J) 3516 Rear Counterweight

The 3516 Engine crankshaft has a new forged counterweight in the number 16 position. The new counterweight is thicker and has shorter "ears" overhanging the counterweight pad. These changes improve the robustness of the counterweight. All 3516 Engines built after September 2014are equipped with the improved rear counterweight.

Counterweights It is recommended that the rear counterweight on machine engines be removed and both surfaces of the joint inspected at every rebuild. For crankshafts other than those in machine engines, the removal and inspection of the rear counterweight is not required at rebuild. Upon inspection, if fretting is found, then inspect the other counterweights and counterweight pads on the crankshaft. If fretting is found and is beyond the acceptable limits, then machine the crankshaft counterweight mounting pad. The machining specifications are found in the "Counterweight Mounting Pad" section of this document. Every time the 3500 crankshaft counterweights are removed from the crankshaft both surfaces of the joint must be inspected, new mounting hardware must be usedr080crc15 and a Caterpillar: Confidential Yellow balance check must be performed. https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&called…

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The counterweights are critical for maintaining crankshaft rotational balance within the engine. Anytime the rotational mass of the crankshaft is altered, including simple replacement of the mounting hardware the crankshaft must be inspected for balance. The balancing information is found in the "Balancing 3500 Crankshafts" section of this document. Counterweight Design Former counterweights were made from plate steel. The former counterweights also had an outside radius of 222.0 mm (8.74 inch). Current counterweights in all 3500 engines are made from forged steel. Counterweights are available in the 222.0 mm (8.74 inch) outside radius and in the 225.0 mm (8.86 inch) radius. All counterweights are replaced with forged steel counterweights when the crankshaft is reconditioned. Cylinder blocks have also been changed to provide additional clearance for the counterweights with a larger radius.

NOTICE Crankshaft assemblies with the 225.0 mm (8.86 inch) radius that listed in Table 25 cannot be used with the former cylinder blocks. The larger counterweights will contact the block and possibly cause it to crack.

Inspection and Reusability No machining is permitted on the mounting surface of the counterweight. If the surface is worn or badly pitted, then the counterweight cannot be used again and must be replaced. Numbering the Crankshaft The number for the position that is stamped on the counterweights will no longer be stamped on the crankshaft. The counterweights are still numbered. Table 27 shows the number of counterweights per crankshaft and the number sequence for the counterweight that is associated with each crankshaft. Table 27 Numbering on Crankshafts for Counterweights Number of Cylinders

Quantity of Counterweights

Numbering for Counterweights

8

6

1 to 3 6 to 8

12

12

1 to 12

16

16

1 to 16

20

20

1 to 20

Illustration 245

g01257323

This example is the former sequence for numbering a crankshaft on a typical 3500 Engine crankshaft.

Illustration 246

g01257344

This example is the current numbering sequence on a crankshaft for a typical 3500 Engine crankshaft.

Illustration 245 shows the former numbering sequence. Illustration 246 shows the current numbering sequence. These Illustrations show that the counterweights are numbered with a "1" at the front end of the crankshaft. The crankshaft is numbered with an "8", "12", "16", or "20" at the rear end of the crankshaft. The number at the rear end depends on the size of the engine.

Illustration 247

g01257365

This example is the front face of a typical 3500 Engine crankshaft.

The front end of the crankshaft can be identified by the letters "FRT STD" that are stamped on the front face of the crankshaft. Refer to Illustration 247. The letters "FRT STD" go toward the front of the engine on a standard rotation engine. Standard rotation is counterclockwise when the engine is viewed from the rear.

Illustration 248

g06174324

This example is the rear face of a typical 3500 Engine crankshaft with the locator pad.

The rear end of the crankshaft can be identified by the two locator pads on the flange at the rear end of the crankshaft. Refer to Illustration 248. The crankshaft sequence number can be found on the rear end of the crankshaft. On older crankshafts, a pair of three-digit numbers the two locator pads. On typical crankshafts the sequence number can be found on the rear hub between the two locator pads. The rear end of the crankshaft can also be identified by the letters "FRT REV" that is stamped on the rear face of the crankshaft. An example is shown in Illustration 248. The letters "FRT REV" go toward the front of the engine in a reverse rotating engine. Reverse rotation is clockwise when the engine is viewed from the rear of the engine. This means that the rear end of the crankshaft goes toward the front of the engine in a reverse rotating engine.

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Note: The number one counterweight must always be on the "FRT STD" end of the crankshaft. This rule is true whether the "FRT STD" end of the crankshaft goes toward the front of the engine or rear of the engine. The last counterweight must always go on the "FRT REV" end of the crankshaft. Counterweight Mounting Pad

Illustration 249

g06174328

Counterweight mounting pad (F) Area to measure flatness on counterweight mounting pad.

The counterweight mounting pad on the crankshaft may be resurfaced as needed to remove pitting and to restore proper flatness. Refer to Illustration 246 for surface texture specifications and area to measure flatness. Mounting pads with minor amounts of pitting can be used again. The pitting is acceptable if the pitting does not extend beyond the centerline of the bolt hole. Burrs or raised material can be removed from the mounting pad by using a 30.0 mm (1.2 inch) wide file. First, remove the dowel, then use light pressure and remove only the material which prevents the counterweight from making complete contact with the mounting pad. The mounting pad must be flat across the entire surface to be used again. Measure flatness with a machined straight edge and feeler gauge across distance (L) as shown in Illustration 246. The mounting pad flatness for 3500 engines must be within 0.038 mm (0.0015 inch).

Illustration 250

g06174331

Distance from centerline of crankshaft to surface of the mounting pad.

Refer to Illustration 249. Measure distance (G) from the centerline of the crankshaft to the surface of the mounting pad. For Cat 3500 crankshafts the minimum crankshaft mounting pad reuse measurement must be no less than 116.12 mm (4.572 inch). Note: Remove the minimum amount of material from the mounting pad to eliminate any fretting. Machining the counterweight mounting pad will alter the distance of the counterweight from the center of the crankshaft and will affect balance. If the mounting pad is machined, then the crankshaft must be balanced. For further guidance on balancing the crankshaft, refer to the "Balancing 3500 Crankshafts" section within this document. 3508 Off Highway Truck Engine crankshaft mounting pads must be inspected and, if needed, salvaged before mounting the counterweight. On certain 3508 crankshafts, the counterweight pad interferes with the counterweight. This interference can cause the counterweight to crack and become damaged. Inspection of the counterweight and counterweight mounting pad is critical before reuse.

Illustration 251

g03780136

3508 Counterweight Mounting Pad inspection illustrating excess width.

Illustration 251 is an example of a 3508 counterweight pad being inspected using a shop made gauge. Refer to Special Instruction, REHS9218, "Crankshaft Rework Procedure for Certain 3508 Off-Highway Truck Engines" for further inspection guidance .

Illustration 252

g03781353

Interference marks on 3508 counterweight mounting pad.

Illustration 253

g03781354

Cracked counterweight as a by-product of mounting pad interference.

A visual inspection of the counterweight mounting pad and the counterweight are also good indicators of interference. Refer to Illustrations 252 and 253 for examples of interference damage. Counterweight Bolts The 4W-6358 Bolt has been canceled and must not be used. The 4W-6358 Bolt can be identified by the marking “CWT” on top of the bolt.

Illustration 254

g06174334

Measure the counter bore diameter to determine the washer size. (H) Counter-bore diameter

Before ordering new bolts and washers, first determine the size of the washer. If dimension (H) in Illustration 251 measures 32.5 mm (1.28 inch), use the 128-4845 Bolt Assembly. If the hole measures 27.0 mm (1.06 inch), then use the 7E-4201 Bolt and the 7E-4725 Hard Washer combination.

NOTICE With a thicker flange on the counterweight bolt, there is less engagement surface for a socket. Use special care when tightening the counterweight to avoid damage to the socket and the bolt head. r080crc15 Caterpillar: Confidential Yellow

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If one bolt fails, then the counterweight should be removed and both sides of the joint (the counterweight and counterweight pad) carefully inspected. If both surfaces are acceptable for reuse, then the counterweight should be reinstalled in the same orientation using new bolts in all three holes. Whenever a counterweight bolt is removed, the bolt must be replaced with a new bolt.

Balancing 3500 Crankshafts All 3500 crankshafts leave Caterpillar factories balanced at 3.5 gm or less. Salvage machining operations will alter the rotational mass unevenly around the axis of rotation and crankshaft unbalance occurs. Crankshaft unbalance produces vibration which can cause excessive bearing wear, noisy operation, failure of structural parts, and a reduction in overall engine efficiency. Crankshaft balancing is made dynamically in two planes perpendicular to the rotational axis. Planes J and K in Illustration 253 illustrate the two planes to balance in 3500 engines. Proper grinding and polishing the crankshaft has not been shown to alter the crankshaft balance out of factory specifications. If doubt occurs if the crankshaft should be balanced after machining, then check the balance of the crankshaft. It will be the responsibility of the individual dealership to acquire balancing equipment or the service of a reputable balancing company. If any of the following has been performed, then the crankshaft must be inspected for proper crankshaft balance. Grinding a select number of journal surfaces rather than all the main or all the pin journals. Replacement of counterweight hardware. Machining of crankshaft counterweight pad(s). Replacement of counterweight(s). For all 3500 engines, dynamic balance specifications are 3.5 gm at 200 RPM.

Illustration 255

g06174338

Typical 3500 crankshaft and counterweight.

Drill as necessary in Zone (A) and Zone (B) so that dynamic unbalance in Planes (J) and (K) does not exceed 3.5 gm. Hole depth in Zone (A) must not exceed 48 mm (1.89 inch). A through hole is permitted in Zone (B). Do not modify an existing balance hole. Keep balance hole on counterweight front to rear center line. Use a maximum drill bit size of 31.25 mm (1.25 inch) to drill balancing holes.

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Note: If necessary, drill as above in other counterweights. Zone (A) and Zone (B) restrictions apply to all counterweights drilled for balancing. Balancing 3508 Crankshafts Bobweights mounted on each pin are required for balancing the 3508 crankshaft. Refer to the following table for the bobweights for your specific crankshaft. Table 28 Weights of the bobweights for 3508 series crankshafts Crankshaft Part Number

Weight of Bobweight

7E-3912

15.7 kg (34.61 lb)

7E-4899

15.7 kg (34.61 lb)

7W-0210

15.57 kg (34.326 lb)

9Y-3798

15.57 kg (34.326 lb)

152-4994

15.7 kg (34.61 lb)

152-7625

16.3 kg (35.94 lb)

241-0221

16.3 kg (35.94 lb)

The 3508 B has counterweights with trimmed ears in the #1, #3, #6 and #8 counterweight locations. The #2 and #7 counterweights do not have trimmed ears. If a 3508 B counterweight needs to be replaced, then use a 188-0478 Counterweight and manufacture it to the specifications found in Illustrations 255 through 256. After trimming, then ensure that all cuts ears are free of burrs all around. Note: Balance hole requirements for the 3508B counterweights are the same for all 3500 counterweights as listed in Illustration 253.

Illustration 256

g06174551

3508 Counterweight #1 As seen facing front hub. (J) 42.2 ± 2 mm (1.66 ± 0.08 inch) (K) 74 ± 2 mm (2.91 ± 0.08 inch)

Illustration 257

g06174552

3508 Counterweight #3 As seen facing front hub. (L) 59.5 ± 2 mm (2.34 ± 0.08 inch) (M) 14.7 ± 2 mm (0.58 ± 0.08 inch)

Illustration 258

g06174554

3508 Counterweight #6 As seen facing front hub. (P) 39 ± 2 mm (1.54 ± 0.08 inch) (N) 17.1 ± 2 mm (0.67 ± 0.08 inch)

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Illustration 259

g06174556

3508 Counterweight #8 As seen facing front hub. (Q) 95.9 ± 2 mm (3.78 ± 0.08 inch) (R) 84.1 ± 2 mm (3.31 ± 0.08 inch)

Balancing 3516 Crankshafts The 3516 crankshaft has a unique number 16 counterweight. The 448-8941 Counterweight has the ears removed and is a required update at overhaul on machine engines. The counterweight update is not required on applications other than machine engines. Use the following specifications for balance hole drilling.

Illustration 260

g06174559

3516 number 16 counterweight.

Drill as necessary in Zone (A) so that dynamic unbalance in Planes (J) and (K) in Illustrations 253 and 257 does not exceed 3.5 gm. Hole depth in Zone (A) must not exceed 48 mm (1.89 inch). Do not modify an existing balance hole. Keep balance hole on counterweight front to rear center line. Use a maximum drill bit size of 31.25 mm (1.25 inch) to drill balancing holes.

Counterweight Installation and Bolt Torque There are two procedures for tightening the counterweight bolts. One procedure is for 3508 Engines. The other procedure is for 3512 Engines and 3516 Engines.

NOTICE Each counterweight has a number and must be installed in the same position as the corresponding number on the crankshaft mounting pad. Failure to install the counterweights in the correct position can damage the crankshaft when the engine is run.

Make sure that the 7N-2003 Dowels are placed correctly and install the counterweights on the crankshaft according to the following steps. 3508 Engines 1. Single wrench or single spindle bolt sequence by position Outer, Outer, Inner. 2. Before assembly, put 334-0519 Grease on the bolt threads, the shank, the underside of bolt head, and the washer. 3. Tighten all bolts for the counterweights to 200.0 ± 5.0 N·m (150.00 ± 4.00 lb ft). 4. Loosen all bolts in the counterweights. 5. Tighten all bolts in counterweights to 70.0 ± 5.0 N·m (50.00 ± 4.00 lb ft). 6. Turn each bolt for an additional 120.0 ± 5.0 degrees. 3512 Engine and 3516 Engine 1. Single wrench or single spindle bolt sequence by position Outer, Outer, Inner. 2. Before assembly, put 334-0519 Grease on the bolt threads, the shank, the underside of bolt head, and the washer. 3. Tighten all bolts for the counterweights evenly to 70.0 ± 5.0 N·m (50.00 ± 4.00 lb ft). 4. Turn each bolt for an additional 120.0 ± 5.0 degrees.

Crankshaft Salvage Overview Use the following flows charts to help process the crankshaft from raw core to final product.

Illustration 261 g06287788 Inspection flow chart

Illustration 262 g06287792 Machining Flow Chart

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Preparing to Grind the Crankshaft Crankshaft Bearings The crankshaft bearings reveal the health of the bottom end of an engine at time of disassembly. Assessment of the crankshaft bearings is a critical step in the crankshaft salvage process. This assessment is as important as inspection of the crankshaft. The bearings can reveal many underlying issues with the crankshaft in particular, but also with the engine as a whole and the conditions in which the engine operated. Having the physical crankshaft main and rod bearings on hand throughout the crankshaft salvage process will help the decision-making process go smoothly with justification for the actions taken. If the physical bearings are impossible to retain, then a highquality photograph of both the front and back of the bearings should be used. Proper bearing analysis can determine crankshaft straightness, journal profile, journal taper, prior rebuild quality, block, and connecting rod bore condition and operating conditions. Inspect the crankshaft bearings for any potential underlying engine issue.

Equipment This section will outline the equipment necessary to salvage a Cat crankshaft. The equipment needed to grind or polish the crankshaft must be inspected prior to any work being done on the crankshaft. Use this section to help identify what equipment is needed and how to inspect the equipment properly.

Illustration 263

g01726399

Typical example of a crankshaft grinder.

Prepare the equipment for grinding according to the recommendations from the manufacturer. Many machines for grinding are available, Illustration 263 is an example of one grinding machine. Each model has specific controls and procedures that must be followed to get acceptable results. Selecting the correct size of grinding machine is important. Verify that the machine for grinding has the necessary capacity for the crankshaft that is being ground. To grind the largest Cat crankshaft, the machine for grinding must be able to support a length of 4340 mm (171 inch) and can support a diameter of 275 mm (11 inch). If the dealership is preparing to grind all models of Cat crankshaft, then the dealer will need a machine capable of grinding the 3618 crankshaft. Refer to Table 29 for the approximate lengths of the larger Cat crankshafts. Note: Table 29 is sorted by approximate length of crankshaft. Table 29 Crankshaft Dimensions Sales Model

Approximate Length

Approximate Diameter(1)

D346 D343 3406 3408

1270 mm (50.0 inch)

125 mm (5.0 inch)

C27 C32

1285 mm (51.0 inch)

125 mm (5.0 inch)

3412

1300 mm (51.18 inch)

125 mm (5.0 inch)

D379

1450 mm (57.0 inch)

150 mm (6.0 inch)

3508

1462 mm (58.0 inch)

135 mm (5.3 inch)

D348

1500 mm (59.0 inch)

135 mm (5.3 inch)

D353

1750 mm (69.0 inch)

130 mm (5.1 inch)

D342

1880 mm (74.0 inch)

110 mm (4.3 inch)

D349

1900 mm (75.0 inch)

135 mm (5.3 inch)

3512

1972 mm (78.0 inch)

160 mm (6.3 inch)

D398

2000 mm (79.0 inch)

150 mm (6.0 inch)

3516

2510 mm (99.0 inch)

160 mm (6.3 inch)

D399

2591 mm (102.0 inch)

175 mm (6.9 inch)

3606

2921 mm (115.0 inch)

250 mm (9.8 inch)

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3608

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3734 mm (147.0 inch)

250 mm (9.8 inch)

3612

3226 mm (127.0 inch)

250 mm (9.8 inch)

3616

4140 mm (163.0 inch)

250 mm (9.8 inch)

3618

4340 mm (171.0 inch)

275 mm (10.8 inch)

(1)

Diameters listed are rounded up and not reuse specifications.

Equip the machine for grinding with the following items: Double groove chucks Splash Guards Ample cooling flow Dressing attachment Attachment for continuous measurement (Arnold Gauge) Polisher Various sizes of grinding wheels Manufacturers of Grinding Machines There are many manufacturers of grinding equipment that are around today. Several manufacturers are listed below. AZ Machine Tools Viale dell'elettronica 20 Thiene (Vicenza) 36016, Italy www.azspa.it Telephone +39 0445 575543 Fax +39 0445 575756 Berco S.p.A Via 1° Maggio, 237 44034 Copparo (Ferrara) Italy http://www.berco.com Telephone +39 0532 864111 Fax +39 0532 864259 A brief search on the Internet will find several companies that sell used equipment. The web site below contains information on used equipment. MachineTools.com Inc. 5720 W Maple Road West Bloomfield, MI 48322 U.S.A. www.machinetools.com Telephone 785-965-2659 Grinding Machine Inspection Periodically the grinder must be inspected for accuracy. The following items must be checked at least annually, although the frequency of inspection can increase with increased usage. A grinder that is used daily should be inspected for accuracy at least monthly. Make note of all measurements and provide the list to the repair technician. Discrepancies must be resolved by a qualified millwright or machine repair technician. 1. Inspect the faceplate. Remove the chucks and inspect faceplate runout. No more than 0.025 mm (0.001 inch) of runout is acceptable. 2. Inspect the chucks. Attach the chucks and inspect for centering. Chuck a machined test bar with at least 8" extending past the chuck. Measure the runout, runout must be within 0.003 mm (0.00012 inch) next to the chuck and within 0.005 mm (0.00020 inch) at the far end of the bar. Repeat this procedure for both chucks. If the runout is more than specified, then new chucks may be needed. Seek advice from a machine repair expert. 3. Inspect the table for wear. Attach a dial indicator to a part of the machine that can travel side to side such as the grinding wheel, wheel spindle housing, or front gearbox. Place the indicator such that the tip will travel from the worn portion of the table to the unworn portion of the table. Check the top, back, and front of the table. 4. Inspect for tail stock wear. r080crc15

Move the tail stock to an unworn portion of the table. Set a dial indicator against the chuck. Tighten only one of the bolts. Zero the indicator. LoosenConfidential the tight bolt Caterpillar: Yellow and tighten the other hold down bolt. If the chuck moves the indicator at all, then there is wear. The wear must be corrected before any other measurements are https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&called… 120/139

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taken. Seek advice from a machine repair expert. 5. Inspect the machine for taper. If there is any movement recorded from Step 4, then the taper must be corrected before proceeding. This step involves inspecting for tapered wear on the ends of the table of the machine. a. Clamp the test bars into the chucks. b. Use a dial indicator to zero the bars as close to the chucks as possible. Mark the location on the bars where the measurement was taken. c. Use a C-clamp, a dial indicator, magnetic base, and tongue depressors as protection and attach the dial indicator to the grinding wheel. Use the tongue depressors as clamping pads between the magnetic base and grinding wheel, the c-clamp and the magnetic base, and the c-clamp and the grinding wheel. d. With dial indicator clamped to the grinding wheel, move the grinding wheel toward the head stock. Bring the indicator tip to where the tip was zeroed in Step 5b. Find the high point of the test bar and adjust the indicator to zero. e. Slightly rotate the grinding wheel to clear the indicator of the test bar. Move the indicator to the tail stock test bar where the indicator was zeroed in Step 5b. Find the high spot by slowly moving the indicator to find the high spot. The indicator should read zero. f. If the indicator does not read zero, then the tail stock taper adjustment must be moved until a zero reading is obtained. g. Complete Step 5a through Step 5f until the taper is removed. 6. Inspect the machine alignment. This inspection is to ensure the center of the head stock and tail stock bearings are aligned. a. Chuck a section of bar stock at least as long as the crankshaft to be ground. b. Measure runout at both ends to ensure bar stock is centered on both the head stock and the tail stock. c. Manually grind an equal amount off each end of the bar stock. d. Inspect the diameter of the ground section. The diameters should be equal. If the diameters are not equal, then the machine is not aligned. The machine needs adjustment from a qualified machine repair technician. Steady Rests Proper steady rest size and placement are critical to a successful crankshaft grind. The steady rest should support the crankshaft from underneath at a negative 10° to 15° angle away from the grinding wheel. The steady rest should also support the crankshaft on the opposite side of the grinding wheel. The forces on the crankshaft during the grinding process can introduce errors if proper machine setup is ignored.

Illustration 264 g06174707 Improper steady rest setup.

The steady rest shown in Illustration 264 is an improper setup. The lower support of the steady rest is not supporting the lower portion of the crankshaft. As the grinder applies pressure, the grinder will cause the crankshaft to move or "roll" out of the steady rest support.

Illustration 265

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Proper steady rest setup (1) Grinder Wheel (2) Crankshaft (3) Steady Rest (A) Angle of support (10° to 15° from vertical)

The steady rest in Illustration 265 shows a proper steady rest setup. The steady rest is supporting the crankshaft from below and is within Angle (A) of vertical. Ensuring that the steady rest is supporting at a positive angle will help force the crankshaft into the steady rests for support . If the dealership will grind various crankshafts, then an adjustable steady rest would be recommended to accommodate the variety of crankshaft sizes. Grinding Wheels Caterpillar prefers using a Norton 4728-1994 aluminum oxide grinding wheel. The Norton wheel is what Caterpillar uses to manufacture the crankshaft and have had superior results. Aluminum oxide wheels have been found to yield the best results when grinding Cat crankshafts. Check with the manufacturer of the grinding wheel to verify that the grinding wheel is of the correct size, grade, and grit for the job. Caterpillar approves grinding wheels made of aluminum oxide, ceramic, SolGel, and CBN. Determine the grinding wheel size from the width of the crankshaft journal. The widths of the different journals are found in the applicable Reuse and Salvage Guideline, "Specifications for Crankshafts" manual found in the "Service Letters and Technical Information Bulletins" section of this document. The best practice is to use a grinding wheel slightly wider than the bearing width and can grind an entire journal with one plunge. A grinding wheel with the capability of grinding the complete journal with one plunge will provide a better journal profile. A better profile of the journal will increase the life of the bearings. Procedure to Inspect the Grinding Wheel Inspect the grinding wheel for cracks before mounting on the grinder. To inspect the grinding wheel for cracks, hang the grinding wheel from a hook so all sides of the r080crc15 grinding wheel can be easily seen. Use a nonmetallic object such a hammer handle or a screwdriver handle, tap the grinding wheel lightly in several locations a few inches Caterpillar: Confidential Yellow https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/productsearch/productheaderinfoframeset.jsp&called… 121/139

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from the perimeter. A grinding wheel that has no defects will give a distinct ring sound. A grinding wheel that has defects will give the sound of a dull thump when tapped. Never use a grinding wheel that has any type of defect. Do not use a grinding wheel that gives the sound of a dull thump.

Illustration 266 g01726442

Verify that the grinding wheel has been balanced. Procedure to Dress the Grinding Wheel While you are dressing the grinding wheel, consider the following factors. Sharp diamond RPM Feed rate of the diamond Depth of cut Frequency of grinding wheel dressings can vary and is not an exact interval. Numerous factors will affect how often the grinding wheel will need to be dressed. Some factors include: Grinding wheel hardness and diameter Crankshaft journal diameter Operator experience and feed rates Note: For example: consider two crankshafts with 0.025 mm (0.0010 inch) material that is left and the same width of the journal. The journal with the larger diameter will load up a grinding wheel faster than a journal with a smaller diameter. The grinding wheel will begin to chatter and the wheel will burn the crankshaft after loading up with steel particles. The use of a sharp diamond is necessary for all types of dressing applications. Keep the rpm of the grinding wheel consistent during dressing and grinding. See the recommendations from the manufacturer for the type of grinding wheel that is used. The type of grinding determines the feed rate that the diamond dresses the grinding wheel. If heavy stock needs to be removed from the crankshaft, then move the diamond across the grinding wheel faster. Dressing the grinding wheel fast will give the grinding wheel a rougher texture. The rough texture will cause the grinding wheel to load up at a slower rate.

Illustration 267

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Grinding wheel face being dressed.

Illustration 268

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Side of grinding wheel being dressed.

Move the diamond across the grinding wheel at a slower rate when you are making the final pass to make a smooth surface texture. The smooth surface texture makes long term grinding difficult because the grinding wheel will load up too fast. Marks from chatter and burning will result on the crankshaft from a loaded grinding wheel. When the grinding wheel gets loaded with material, then use a carbide stick between dressings. When removing material from the grinding wheel, the wheel must be dressed in a two-step process. The two steps that follow will yield a superior texture on the grinding wheel. Note: Always run coolant during the process of dressing the grinding wheel. If coolant is not used, then the diamond will heat up rapidly and damage the wheel. Coolant flow in Illustration 267 is shut off for photographic purposes. 1. Perform two rough passes removing 0.0508 mm (0.002 inch) on each pass. 2. Perform one final pass removing 0.0254 mm (0.001 inch) of material. 3. Dress the side of the wheel and corner radius after the cutting face of the wheel has been dressed. This dressing will help blend the face profile into the side of the wheel. Between diamond dressings, a carbide stick can be used to clean the cutting face.

Illustration 269 g01726614

The side of the grinding wheel must be dressed periodically. Keep the grinding wheel dressed so the perimeter is flat and blends into the fillet smoothly. Refer to Illustrations 267,268, and 269 for examples of dressing a grinding wheel. If the grinding wheel is not dressed properly, the grinding wheel may grind a step into the fillet on the crankshaft journal. Any step that is left on the crankshaft journal will cause a stress riser in the crankshaft.

Illustration 270

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Checking the profile of a grinding wheel.

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After dressing the grinding wheel, the profile and fillet radius of the wheel can be easily checked with a tongue depressor. Refer to Illustration 270 for an example of radius inspection. Keep your fingers clear of the wheel, and gently press the side of the tongue depressor into the grinding wheel. The wheel will grind away a negative impression into the tongue depressor.

Illustration 271

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Inspecting the crankshaft grinding wheel radius.

Using a radius inspection gauge tool, check the impression to ensure that the wheel is dressed properly. Adjust the wheel as needed. When the wheel is adequately dressed, then the wheel will be ready for grinding. The depth of the cut will be a factor when the surface texture of the wheel is being determined. The depth of approximately 0.127 mm (0.0050 inch) is recommended when a rough surface texture is necessary. The depth of approximately 0.025 mm (0.0010 inch) is recommended when texture grinding is necessary. Balance the Grinding Wheel After dressing the grinding wheel, then the wheel must be balanced. If the grinding wheel is out of balance, then the loping or throwing effect of the wheel can cause a situation for uneven grinding to occur. As the grinding wheel spins at a high rate of speed, the imbalance can cause the wheel to "throw" itself into the crankshaft taking a deeper cut in that area than the operator intended. As the grinding process continues, this situation will progressively get worse and create an out of round journal. The supplier of the grinding wheel will provide you with more details about the grinding wheel and with information about mounting, balancing, and tightening the grinding wheel. Coolant The type and the quantity of the coolant that is used is crucial to the grinding process. Some key features of the coolant are listed below: Daily skimming of sludge and oil Daily concentration inspection Proper flow of coolant across the crankshaft during grinding, the grinding wheel, and steady rest Periodic replacement of the coolant

Illustration 272

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Inadequate coolant flow. Coolant is not free flowing across the entire width of the grinder wheel.

Illustration 273 g03653598 Adequate coolant flow

Whenever the grinding wheel is in contact with the diamond or the crankshaft, a constant flow of coolant must be supplied. Failure to keep an adequate flow of clean coolant when grinding the crankshaft can introduce grinder burn and potentially ruin a reusable crankshaft. Illustrations 272 and 273 demonstrate two extremes in coolant flow volume. The coolant has many functions. The coolant keeps the diamond, the grinding wheel, and the crankshaft from becoming overheated. The coolant also cleans the process by carrying away the steel from the crankshaft and residue from the grinding wheel as the wheel breaks down. Follow the recommendations of the machine manufacturer for the proper type of coolant and the proper concentration. Measuring Instruments Proper crankshaft salvage will require various measuring instruments. Crankshaft salvage requires at least: Accurate and stable inspection bench. Diameter and profile measurement tooling. Air gauges are recommended. Surface texture analyzer. Hardness tester. Ultrasonic testers are preferred. Dial indicators and tips for measuring diameter and runout. The use of an accurate in-process grinding gage or "Arnold" gage is critical to a successful grind. The dial indicator on the grinding gauge must be accurate and at a scale of 0.01270 mm (0.0005 inch).

Illustration 274

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Typical Air Gauge and calibration blocks used for crankshaft measurement.

r080crc15 Before, during, and after crankshaft salvage the crankshaft journals must be measured and inspected continuously. This constant measuring is necessary to ensure that Caterpillar: Confidential Yellow small deviations do not ruin a crankshaft.

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Caterpillar prefers the use of an air gauge for all critical measurements such as journal diameter and profile. A properly calibrated air gauge is the most accurate measuring instrument that is readily available for the journal diameters. With multiple air rings combined on one head, an air gauge can provide accurate measurements of diameter, profile, and roundness in one measurement. Refer to Illustration 274 for an example of an air gauge and calibration blocks. If an air gauge cannot be obtained, then the use of snap gauges is acceptable. A snap gauge is an acceptable method for measuring the diameters of the journals. The use of a snap gauge is an efficient method of measuring the diameters of the journals. A snap gauge is better than a micrometer because the percent for human error has been greatly reduced. A snap gauge can measure diameter accurately and repeatedly, but journal profile is difficult and time consuming to measure with a snap gauge. The final choice for measuring the diameters of the journals if neither air nor snap gauges are available, is using a micrometer. The micrometer must be calibrated correctly by using the gauge that generally comes with the micrometer. The same feel that is used to calibrate the micrometer to the gauge should be used to measure the crankshaft. Each person that uses the micrometer may have a different feel and may not achieve the same reading making the micrometer the least reliable method. Micrometers are difficult to measure diameter and journal profile repeatedly. Complete the entire inspection form with the measurements found, and keep the form with the crankshaft during the process of reconditioning. Note: Any instrument that is used to measure the diameters of the journals should be kept at the same temperature as the crankshaft. The tools and the crankshaft will stay the same temperature in a climate-controlled room. The gauge blocks must be the same temperature as the crankshaft to have an accurate reading. A surface texture analyzer is necessary to check the surface texture of the journals. For the proper specifications on the surface texture that is required after polishing. Use a Non-Destructive hardness tester such as an Equotip tool or ultrasonic tester to check the hardness of the crankshaft journals without damaging the crankshaft. A dial indicator should be used to check for Total Indicator Runout (TIR). Check the crankshaft before any grinding. If the crankshaft has any TIR, determine the cause of the TIR. The cause could be any of the following reasons: Incorrect clamping in the chuck Debris in the centers Bent crankshaft The list below contains manufacturers that make measuring tools. These manufacturers have on-line catalogs. Air Gauge Manufacturers Mahr Federal http://www.mahr.com 1144 Eddy Street Providence, RI 02905 (800) 343-2050 Snap Gauge and Micrometer Manufacturers Mitutoyo America Corporation www.mitutoyo.com All contact information is on the internet. Brown & Sharpe 250 Circuit Drive North Kingstown, RI 02852 www.brownandsharpe.com 800 343-7933 Starrett 121 Crescent Street Athol, MA 01331 U.S.A. www.starrett.com 978 249-3551 Accessories for Grinding Machines Grinding Wheels Norton Company www.nortonabrasives.com/ All contact information is on the internet. Tyrolit Swarovskistrasse 8 6130 Schwaz, Austria +43 52426060 Coolant Cimcool Global Indstrial Fluids Milacron Marketing Co. 3000 Disney St. Cincinnati, Oh. 45209 www.cimcool.com/ Telephone 888-246-2665 Fax 800-205-3293

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Chemtool Inc. 8200 Ridgefield Road Crystal Lake, Illinois 60039 www.chemtool.com/ Telephone 815-459-1250

Cleaning Prior to anything else performed on the crankshaft, the crankshaft must be cleaned thoroughly. Remove and discard all the oil plugs, ensure that all passages are cleaned, and any varnish is removed from the journals. Some journals will have oil oxidation that will not be removed with chemical cleaning. These journals will need at least a light polish to clean them. If the crankshaft has removable counterweights and the counterweights are to be reused, then be sure to mark the counterweights for proper location and orientation before removal. The counterweights must be placed in the same location and orientation at reassembly. If the counterweight is to be reused, then the counterweight must be reassembled in the same orientation and location on the crankshaft from which it was removed. Proper reassembly is critical to maintain crankshaft balance. Refer to Reuse and Salvage Guidelines, SEBF8187, "Standardized Parts Marking Procedures" for information on marking engine parts. During overhaul the counterweight bolts must be replaced. The torque tightening sequence varies by crankshaft model. The crankshaft must be cleaned using a continuously filtered solvent. Mineral spirits are recommended. All dirt, oil, and debris must be removed from the crankshaft. Flush the oil passes with solvent to ensure that the passages are free of any contaminants. A wire brush can be used to clean the bolt holes. A nylon brush must be used on the oil holes. A wire brush will damage the area around the oil passages. A cone sander can be used to polish the center holes on the crankshaft ends. The crankshaft must be clean enough to meet the ISO 16/13 specifications for cleanliness. After cleaning, rotate crankshaft 360° and use shop air to remove all solvent from the oil holes. Repeat the cleaning procedure as many times as necessary until cleanliness level meets the ISO 16/13 specification.

Crankshaft Inspection This section will outline the process of inspecting Cat crankshafts. The crankshaft must be inspected visually and measured for reuse specifications, before any salvage machining is performed. The inspection will identify if the crankshaft can be reused, salvaged, or discarded. The intent of a pre-salvage inspection is to identify anything that would prevent the crankshaft from being reused or salvaged. Record your inspection findings on a standard form for inspecting crankshafts. There is a form found in Special Instruction, SEHS7949, "Crankshaft Inspection Form" which will aid in this recording process. However, any other suitable documentation is acceptable to document a crankshaft is inspection. Use the flow charts found within the "Crankshaft Salvage Overview" section of this document for an efficient inspection process.

Illustration 275

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Crankshaft supported by two 5P-8637 Supports.

1. Support the crankshaft. If the centers will be used to support the crankshaft, inspect the centers. Verify that the centers are clean and free of all nicks or burrs. The centers may require polishing using an appropriate cone polisher. Place the clean crankshaft in two 5P-8637 Supports or other suitable crankshaft supports. Refer to Illustration 275. 2. Perform a visual inspection for excessive wear or heat-related damage. Perform a visual inspection of the crankshaft. 3. Inspect the journals. Perform a quick inspection on the crankshaft journals to determine if the crankshaft can be salvaged. a. Use a profilometer to measure any defects in the journal surface. The intent is to determine if the crankshaft can be salvaged. If the scratches are too deep for grinding or polishing to salvage, then discard the crankshaft. If the crankshaft can be salvaged, then determine if the crankshaft needs to be ground, polished, or both. b. Use a snap gauge or micrometer with a graduation of at least 0.001 mm (0.00004 inch) and measure the diameter of the crankshaft journal diameter. This measurement does not need to be highly precise, but to determine if there is enough material remaining to salvage the crankshaft. If there is not enough material in the diameter for salvage operations, then the crankshaft must be discarded. To find the journal diameter specifications of the crankshaft being inspected. 4. Measure the crankshaft for straightness. Inspect the crankshaft for any bend by measuring Total Indicator Runout (TIR). Note: A crankshaft that requires straightening must be straightened before grinding. A bent crankshaft cannot be ground straight. If a bent crankshaft is ground, then the stroke of the crankshaft will be altered. If the stroke of the crankshaft has been changed, then the process of combustion will be altered and therefore should not be reused. 5. Salvage machine the Crankshaft

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If the crankshaft is determined that it needs to be salvaged and that the crankshaft can be salvaged, then proceed to salvage the crankshaft. Refer to the section "Procedure to Grind the Crankshaft" within this document for further guidance on grinding the crankshaft.

Procedure to Grind the Crankshaft This section will outline the process necessary to grind aCat crankshafts. Grinding a crankshaft requires extreme accuracy. Most failures that occur after grinding the crankshaft are due to improper grinding procedures or improper inspection procedures. Only properly trained personnel are allowed to grind Cat crankshafts. Personnel must be trained properly in the following areas before grinding a crankshaft: Applied Failure Analysis Proper use of measuring tools, inspection tools, and gauges Proper use of the grinder Troubleshooting procedures

NOTICE Most crankshafts can be returned to service without any salvage machining or with polishing only. Use visual Inspection and magnetic particle inspection to help determine what level of salvage work is required. If in doubt, then polish and inspect first.

The steps that follow reflect the procedures found in Illustrations 261 and 262. Before starting the grinding process, verify that the machine is properly warmed up. The spindle for the grinding wheel should be allowed to run for at least 15 minutes before dressing the grinding wheel. This procedure will ensure that the bearings are warmed up. A new grinding wheel must be dressed at least five times before the first run to ensure that the grinding wheel is clean. If steady rests are to be used, cycle the steady rest at least ten times to ensure proper setup. Ensure that the coolant is continuously flowing during setup. Stop the grinding process if the grinding wheel begins to chatter or begins to burn the crankshaft. Determine the cause of the defect before continuing to grind. 1. Inspect the crankshaft. Perform the visual, magnetic particle, and diameter inspection procedures found in the "Crankshaft Inspection" section of this document. 2. Gather tools and specifications. Gather all the necessary tooling required to measure the critical dimensions on the crankshaft and note the critical dimensions for the crankshaft to be ground. 3. Prepare the grinding wheel. Verify that the correct grinding wheel is properly dressed, balanced, and mounted on the grinder. Refer to the section "Grinding Wheels". Verify that the diameter of the grinding wheel is large enough to prevent the sidewalls of the crankshaft from contacting any part of the grinder. Always dress the grinding wheel before you start to grind a crankshaft. For best results, use a grinding wheel that is slightly wider than the journal. If the grinding wheel is narrower than the journal, then refer to the section "Double Plunge Grinding" within this document for further guidance.

Illustration 276

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Making adjustments to ensure that chucks are centered.

4. Prepare and load the crankshaft. Ensure the rotation of the crankshaft on the grinder is opposite of the direction that the crankshaft rotates inside the engine. Note: Inspect the grinder. If the crankshaft is mounted with a chuck, then verify that the jaws of the chuck are free of dirt and debris. If the crankshaft is mounted with the centers, then verify that the crankshaft and grinder centers are free from dirt and debris. a. Verify that the crankshaft seals and counterweights (if equipped) have been removed. b. Load the crankshaft into the grinder. Secure the crankshaft to the grinder according to the instructions from the manufacturer. The rotation of the crankshaft should be opposite of the direction that the crankshaft would rotate if inside the engine, and opposite of the grinding wheel.

Illustration 277 g03500516

5. Check the alignment of the crankshaft. After chucking the crankshaft, use a dial indicator on a stand and check the runout on both ends of the crankshaft to ensure proper alignment. This check is to ensure that the crankshaft is centered in the grinder and a taper is not ground into the crankshaft.

Illustration 278

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Steady rest installed to the side of the oil hole.

6. Install steady rests if needed. Do not install the steady rest on top of an oil hole. 7. Check the total indicator runout (TIR) on every journal on the crankshaft.

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Use a stand with a dial indicator and make the proper adjustments to eliminate the runout. Some crankshafts will require the use of a steady rest to remove the runout. 8. Grind the journal. Grind the main journals first, then the rod journals. When grinding try to stay on the large end of the specification diameter. This practice will ensure that adequate material remains for the polishing process. a. If the machine has been idle for more than 4 hours or the grinding wheel has been changed, follow the recommended warmup procedure. b. Ensure that coolant flow is constantly flowing and the flow of coolant is at least as wide as the wheel. c. Set the grinder to spin the crankshaft as close to 15 RPM as possible. d. Inspect the journal diameter often with the in-process grinding gage or "Arnold" gage using an accurate 0.01270 mm (0.0005 inch) dial indicator. e. Begin every grind on the middle journals and work toward the end journals of the crankshaft. Once center steady rest is installed and journal is ground true, do not move or adjust the center steady rest. When grinding only remove approximately 0.05588 mm (0.0022 inch) of material with each cut. Grind the journal to approximately 0.025 mm (0.0010 inch) to 0.05 mm (0.002 inch) larger than the textured size to allow for polishing. After every plunge, allow the grinder to spark out 30 to 45 seconds. Note: The size of the journal may vary each time you measure the journal if you do not allow the grinder to spark out every time at the end of every plunge. Allowing the grinding wheel to dwell on the journal without any pressure for 30 - 45 seconds will minimize any potential machining defects.

Illustration 279

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Air gauge inspecting journals in a Caterpillar production facility. (1) Air gauge head (2) Minimum and Maximum specifications (precalibrated) (3) Graphical display of journal profile.

f. Inspect every journal for diameter, profile, and lobing immediately after grinding. Incorporating an inspection step between grinding journals will catch any potential issues with the grinding machine, wheel, or operator before any further damage to the crankshaft. The use of an air gauge makes this procedure faster, easier, and portrays more information than any other measuring equipment. An air gauge instantly measures the crankshaft diameter in multiple locations simultaneously. The air gauge shown in Illustration 279 is taking five diameter measurements simultaneously. Since these measurements are all taken in a straight line across the journal, the display also shows the profile of the journal. The read out portrays if the journal diameter is within specification and the profile of the grind with one quick reading. If the profile was out of specification, then it would cause reason to redress the grinding wheel. Measure every journal for roundness and profile This inspection step is critical to identify any potential mistakes before the mistakes can cause further damage. The use of air gauges minimizes the time spent and maximizes accuracy on this inspection step.

Illustration 280

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Typical example of small fillet dip after grinding.

Illustration 281

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Typical example of inspecting the fillet area. Note the lighted areas around the fillet gauge. This is due to the small dips that were ground in and are acceptable.

g. Inspect the journal fillet area. Inspect the profile of the fillet radius with a radius gauge and flashlight. A small dip is permissible on the crankshaft at the junction of the fillet and bearing journal surface. Illustration 280 is a good example of where dips are acceptable. The area may have a different surface texture that is caused by a grinding wheel that has broken down faster. This rough area is acceptable only in the bottom 20 percent of the fillet. Illustration 281 shows the inspection of a good journal profile. Any dips must be blended smoothly, there must not be any rough edges. 9. Redress the grinding wheel after main journals are ground and before work begins on the rods. Between dressings if the grinding wheel shows signs of clogging, then use a carbide stick to clear the metal deposits. 10. Complete the Steps 8a through Step 8g in the above procedure for the remainder of the journals. For more information about the undersize bearings that are available for your engine. 11. After grinding is complete, the crankshaft must be inspected, oil hole salvaged, cleaned, polished, final inspection, and potentially balanced. Refer to the appropriate sections as necessary within this document for further guidance.

Double Plunge Grinding Using a grinding wheel that is the same width as the journal will produce the best possible results. If necessary, then using a double plunge grind method can be a successful alternative. The double plunge method involves a shallow plunge cut on one side of the journal, moving to the other side of the journal and making a deeper plunge cut and finally sweeping across the whole width of the journal.

Illustration 282

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First plunge in a double plunge method. (1) Grinding Wheel

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(2) Crankshaft Journal

1. Make initial shallow cut. The first cut will be a shallow plunge on one side of the journal. Do not go to the full grind depth, but leave enough material to sweep off later.

Illustration 283

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Second cut in a double plunge method. (1) Grinding Wheel (2) Crankshaft Journal

2. Make second cut. Raise the wheel and traverse to the other side of the journal and make a full depth plunge. Allow the grinder to spark out after plunge is complete.

Illustration 284

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Grinding wheel sweep in a double plunge method. (1) Grinding Wheel (2) Crankshaft Journal

3. Sweep across journal. Do not raise or lower depth of grinding wheel. Slowly sweep the grinder into first cut material. This sweep will create a seamless blending of the two cuts. Remove the grinding wheel only after the sweep is complete.

Post Grinding Inspection After grinding, the crankshaft must be visually inspected and magnetic particle inspected. The steps that follow reflect the procedure found in Illustration 262. 1. Visual inspection for grinder damage. When performing a visual inspection on the crankshaft look for any potential damage induced by grinding. Inspect the journals and fillet areas for signs of chatter, burn marks, or excessive heat. 2. Perform Magnetic Particle Inspection After the crankshaft has been ground but before the polishing procedure, inspect the crankshaft using the magnetic particle inspection. Occasionally the grinding process can reveal or even cause an unseen defect to appear and they must be discovered before further machining is performed. This inspection will show any cracks or damage that was not visible prior to grinding. 3. Oil hole salvage Inspect the oil holes. Use a bore scope to ensure that there is no debris or burrs inside the oil holes. Inspect all the oil hole chamfers. If the crankshaft was ground undersized, then the oil holes will need to be chamfered. If the oil hole chamfers need salvaging, stop and perform that process now. Refer to the section "Oil Hole Salvage" in this document for further guidance. 4. Clean Crankshaft 5. Perform a hardness inspection. 6. Polish Crankshaft Refer to "Polish After Grinding" 7. Take final crankshaft measurement specifications. 8. Clean the crankshaft 9. Use or store the crankshaft.

Oil Hole Salvage Before grinding, it is important to inspect the oil holes of the crankshaft. Inspect the oil hole chamfer to ensure that there are no sharp edges. After grinding, use a bore scope to inspect all the oil passages. Debris and burrs found within the oil hole can be removed with a small ball hone. Refer to the Section "Procedure to Clean Oil Passages" within this document for additional guidance.

Oil Chamfer Salvage If the crankshaft will be ground under size or if during inspection it is found that the oil hole has sharp edges, then the oil hole will need to be chamfered and then deburred.

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Illustration 285

g01397220

Oil hole with sharp edges.

If the oil hole chamfer has been removed or will likely be removed during grinding, then it can be replaced using adequate tooling. A steel chamfer drill bit with lubricant is recommended for oil hole salvage. While cutting the chamfer, it is important the cutting tool used is kept in a straight line with the angle of the oil hole. The holes on the pin journals are at an angle and not tangent to the journal as the main journals are.

Procedure to Clean Oil Passages

Illustration 286

g01397366

Debris found in oil hole.

Use the correct brush with a solvent to clean the oil passages. Refer to Illustration 287. Refer to section "Manufacturers of Grinding Machines" and Table 3 for the correct diameter of the brush to be used.

Illustration 287

g01397329

Use the correct nylon brush to clean the oil passages thoroughly.

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NOTICE Install the brush on a variable speed drill. Operate the drill at 300 rpm. Never operate the drill unless the brush is inside the oil passage.

It is important for the oil passages to be thoroughly cleaned. If debris should remain in the passage ways, then the debris will eventually workits way out in the salvage process or when it is installed in the engine. When the debris comes out it could ruin the surface texture when machining or ruin the engine should it run with dirty oil passages. The brush must go all the way to the end of each oil hole. The oil holes must be cleaned from every possible angle to ensure that the oil holes are cleaned correctly. The oil holes must be cleaned from both the rod journal and the main journal ends. Also, the oil holes must be cleaned through the holes that lighten the crankshaft or the plug end of the oil holes. To make sure that oil passages are kept free of debris, flush all passages with solvent during the procedure to clean oil passages. After the oil passages are thoroughly cleaned, use an air hose and rotate the crankshaft as needed to remove the remainder of the solvent.

Procedure to Polish the Crankshaft Note: If shot peening is to be performed, then the shot peening must be done after grinding but before polishing. Check the dimensions of the radii before starting any shot peening. The crankshaft must meet all specifications. Use caution not to polish the crankshaft excessively. A mirror like texture after polishing is not desirable. A dull matte sheen that meets the surface texture requirements is preferred. Polishing the crankshaft should not remove any substantial amount of material. Polishing the crankshaft should only return the crankshaft to the correct surface texture. If proper polishing techniques are not applied, the surface texture and profile of the journals can be damaged. The media coarseness that is to be used will vary from dealership to dealership by availability. In every case it is always a better idea to start with a higher grit media. Some experimentation will have to be performed at the dealership. There is a large variability in polishing equipment, media, and operator technique that will have a direct result on the texture. Some experimentation in media coarseness, time on the journals, and lubrication may be required to achieve the correct surface texture. The quality of the texture on the crankshaft will directly affect the amount of wear that a bearing will have. A good surface texture will prolong the life of the main bearings, piston bearings, crankshaft, and engine. Note: During rotation, move the polishing belt slowly and evenly across the journal surface into the fillets.

NOTICE Do not attempt to alter surface profile, taper, or diameter when polishing. Polishing the crankshaft should only return the crankshaft to the correct surface texture. The goal of any polishing technique is to achieve the correct journal surface texture by polishing the least amount of time and removing the least amount of material.

Polishing Media Polish Only For instructions on how to perform the polishing procedure refer to the "Steps to Polish the Crankshaft Without Grinding"section found within this document. Most crankshafts that need machine work will only need a light polishing without grinding. When polishing crankshafts it is critical to meet the correct surface texture with the least amount of polishing as possible. Visual inspection and magnetic particle inspection to help determine if the crankshaft in question can be reused as is, need only a polish, or grinding and polishing. If doubt remains, then contact your Cat dealer Service Representative or the Dealer Service Network for further assistance. Normally, a polish only salvage can use a finer media than in a grind and polish situation. The intent of a polish only is to remove any small surface imperfections, discoloration, and achieve an acceptable surface texture. It is imperative not to introduce any additional risks that can come from over polishing. In a polish only situation, use only the following grit media to lightly clean up the journal surfaces : Table 30 Part Number

Description

516-4613

1" X 72" U243 X 16 (P1200) Polishing Belt

516-4615

1" X 72" U245 X 16 (P2400) Polishing Belt

516-4616

55.5 mm X 1828.8 mm U243 X 16 (P1200) Polishing Belt

516-4617

115 mm X 1828.8 mm U243 X 16 (P1200) Polishing Belt

516-4618

121.5 mm X 1828.8 mm U243 X 16 (P1200) Polishing Belt

516-4619

55.5 mm X 1828.8 mm U254 X 5 (P2400) Polishing Belt

516-4620

115 mm X 1828.8 mm U254 X 5 (P2400) Polishing Belt

516-4621

121.5 mm X 1828.8 mm U254 X 5 (P2400) Polishing Belt

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Polish After Grinding If the crankshaft was ground prior to polishing, then it may be necessary to use a coarser media and progress to a finer media. If the crankshaft only needs a polishing to remove superficial journal imperfections, then attempt to use a finer media first. When in doubt, start with a finer grit and go coarser if necessary. Caterpillar uses micron media because that media has the tightest tolerances with regard to range of grain sizes on that media. This tight tolerance means the micron paper will provide a more consistent surface texture than any other media. 50 micron media on first pass and 20 micron media on second pass using a liquid lubricant. P320 grit media on first pass and P800 grit media on second pass using a liquid lubricant.

Oil Hole Washout

Illustration 288

g06174811

Graphical representation of oil hole washout.

A condition known as oil hole washout is a primary danger when polishing a crankshaft. Oil hole washout is difficult to measure and impossible to see. Oil Hole Washout is created by over polishing the crankshaft. Figure 288 is a visual aid to understand the danger of over polishing. When measured on the trailing edge of the oil hole, it should not measure more than 0.005 mm (0.00020 inch) deep. Excessive polishing is the primary cause of an oil washout and leads to bearing and crankshaft failure. As the polishing media passes over the oil hole, the media is pulled into the oil hole and removes extra material from the trailing edge of the oil hole. When too much material is removed from one side of the oil hole, it changes the dynamic of oil flow. Excessive oil will then pass through one side of the oil hole, and wash out of the bearings. This condition will lead to loss of oil lift on the bearings, causing the crankshaft to ride directly on the bearing. When the crankshaft rides on the bearings, heat will be generated and a bearing failure will happen.

Polishing Equipment For more consistent results, Caterpillar recommends using a polisher that is adequate to polish the entire journal width. Superior results can be achieved using a mounted, counter-weight polisher or a clamped jawed polisher. Note: The hand held "bicycle style" is acceptable only in a polish-only situation using 15 micron (P1200) grit media or finer 9 micron (P2400). Using anything coarser than 15 micron (P1200) grit will damage surface texture and journal profile. This type of polisher has too much variability from the operator, media, lubrication, motor speed, and crankshaft rotational speed to be repeatable. The use of this type of polisher can damage the crankshaft.

Illustration 289

g01727173

Illustration of crankshaft to polisher rotation

Polish the journals only while the crankshaft is rotating. Polish the crankshaft in the opposite direction that the crankshaft was ground. The crankshaft should rotate in the same direction that the engine will operate.

Illustration 290

g03566209

Mounted full journal width polisher in a Caterpillar production facility

Illustration 291

g03631256

Clamp jaw polisher in a Cat dealer.

A counterweight polisher such as shown in Illustration 290 is the most efficient to use because some models can be mounted to the grinder and does not require a second machine or set up. A clamp jaw polisher shown in Illustration 291 can provide excellent results. The clamp jaw polisher must be set up in such a way that the machine is set up adequately and does not over polish. When using a counterweighted polisher, set up the equipment such that the polisher will machine the crankshaft in the opposite direction that the crankshaft was ground. Ideally the crankshaft will rotate in the same direction that the engine will operate. The mounted polisher includes a balanced, spring loaded belt arm that glides on linear rails and can accommodate multiple belt widths. An ideal belt width is one that can polish the entire journal width. The clamp jaw style polisher often will turn in both directions, for this type of polisher it is acceptable to spin the crankshaft counter rotation.

Steps to Polishing the Crankshaft After Grinding The procedure that follows is intended for a crankshaft that has been ground under size and must be polished. Due to the polishing media required, this procedure can alter surface profile and can alter the shape of the journal. Great care and proper equipment must be used when performing this procedure. A hand held polisher must not be used for this procedure. Only a counterweighted polisher or a clamp style polisher can produce the results required. 1. Ensure that the crankshaft including oil passages is clean. Take care not to introduce debris between crankshaft and polishing media. 2. Load the crankshaft into the polishing fixture. Ensure that crankshaft is aligned and properly chucked into the polishing fixture. 3. Begin rotating the crankshaft spinning at approximately 15 rpm. 4. Dress the side wall and thrust wall with a dyna-file or equivalent. 5. Load the coarser grit paper (50 micron or P320 grit) onto the polisher. 6. Turn on the coolant or apply the lubricant as needed.

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7. For the first pass polish up to four journals. Use 1 to 2 passes per journal keeping the passes to under 6 seconds each. During rotation, move the polishing belt slowly and evenly across the journal surface into the fillets. 8. Run a second pass over the same 4 journals using 2 to 3 passes approximately 6 seconds each. The surface texture should measure between 0.11 Ra to 0.14 Ra after the 50 micron paper before moving onto the 20 micron paper. 9. Replace the belt with a finer grit paper (20 micron or P800 grit) and repeat Steps 6 through 8 on the same four journals. 10. Replace the belt with a new lower grit belt and repeat Steps 6 through 9 for the remaining journals, polishing four journals at a time. Note: The time to polish varies depending on the condition of the journals and the condition of the belt. A new belt will cut more aggressively than a used belt. After the crankshaft has been ground and polished, make a complete inspection and check all the dimensions. 11. Final crankshaft inspection. Measure the journals for size, taper, straightness, and surface texture. Clean the crankshaft and move to final destination.

Steps to Polish the Crankshaft Without Grinding The procedure that follows should only be used to clean the journal surface due to discoloration or minor raised scratches. It is important not to try to fix any surface defects with a polish only procedure. Polishing the crankshaft in this instance is not intended to alter the shape of the journal. This type of polish only procedure is only intended to improve surface texture and removed oxidized oil. A hand held polisher can be used for this procedure; however, a counterweight polisher or clamp style polisher will produce superior results.

Illustration 292

g03673883

Oxidized journal that can be salvaged with a polish only procedure.

1. Ensure that the crankshaft including oil passages is clean. Take care not to introduce debris between crankshaft and polishing media. 2. Load the crankshaft into the polishing fixture. Ensure that crankshaft is aligned and properly chucked into the polishing fixture. 3. If using a mounted polisher, then begin rotating the crankshaft spinning at approximately 15 rpm. 4. If needed, dress the side wall and thrust wall with a dyna-file or equivalent. 5. Load polishing media into polisher. If using a hand held polisher, use 15 micron (P1200) grit media or finer 9 micron (P2400). Refer to Table 30 for part numbers. 6. Turn on the coolant or apply a lubricant such as WD-40 as needed. 7. With a new belt, polish all the main journals. Slowly traverse the width of the journal ensuring smooth transition across the journal surface. Polishing should take 510 seconds for each pass of the journal. Perform at least 2 passes. 8. After all the main journals are polished, then polish the rod journals in the same manner. If polishing a crankshaft longer than 8 cylinders, then use a new belt on the rod journals. If polishing a crankshaft 8 cylinders or less, then the same belt used with the main journals can be reused. 9. Final Inspection. Measure the journals for size, taper, straightness, and surface texture.

Manufacturers of Balancing Machines CWT Industries LLC 4708 S. Old Peachtree Road Norcross, GA 30071 U.S.A. www.cwtindustries.com Telephone 800-449-1849 Repair Process Engineering has identified CWT Industries as the preferred balance machine tooling supplier for balancing Cat crankshafts. The Repair Process Engineering Team has worked with CWT Industries to ensure that CWT has all the information necessary to build a crankshaft balancer to Caterpillar specifications. If CWT Industries are not chosen for balancing equipment, then the balancing equipment must meet the following requirements: Head driven, not belt driven unit Must use at least three supports for any crankshaft longer than a 3512 crankshaft.

Procedure to Shot Peen 3512, 3516, and 3524 High Displacement Crankshafts

Illustration 293

g01988370

Almen gauge and Almen strips that have been shot peened

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Adjust the equipment so that all designated areas receive specified coverage. The number of passes and the duration of each pass should be established. A test fixture is required to perform Almen strip tests. An Almen gauge is required for measuring the arc height of test strips. Suitable test fixtures can be made by attaching test strip holders to dummy parts at the proper positions. The velocity and direction of the stream on the test strips should simulate the stream on the actual parts. Standard test strips, holders for the strips, and Almen gauges in SAE Standard J442 should be used for measurements and control.

Preparation and Completion of the Almen Strip Test

Illustration 294 g01988335 Fixture for Almen strip test

1. Machining the crankshaft must be complete before the fillets are peened. 2. The fixture for the Almen Strip Test should be installed into the machine and all adjustments must be performed for the test. The holders for the test strips should be mounted to the fixture at the proper position and distance. Proper mounting will result in more accurate measurements of the test strips. Proper mounting will also result in the proper machine adjustments for meeting specifications. The following will be tested during this operation: Size of media Flow rate Air pressure Coverage 3. To measure the intensity of the stream, attach the test strip to the holder. The test strip should be perpendicular to the flow of the stream in the position of the area that will be shot. This will be repeated for each area that will undergo the shot peening. 4. After the test is complete, label the Almen strips. Remove the strips from the fixture. An Almen gauge must be used to measure the arc height of the Almen strip. Several tests may be needed to obtain the proper coverage.

Specifications Table 31 Specifications Media

S280-M Ervin Industries

Shot Flow Rate

15 ± 1 kg (34.0 ± 2.0 lb) per minute

Air Pressure

345 ± 7 kPa (50.0 ± 1.0 psi)

Almen Strip Arc Height

0.425 mm (0.0167 inch) and 0.525 mm (0.0207 inch)

Coverage

100 percent

Note: The S280-M is an SAE specification. Any manufacturer of the media material can be used as long as the media meets the SAE S280-M specification.

Preparing the Crankshaft for Shot Peening

Illustration 295 g01988372

1. Thrust faces must be masked to prevent peening on this surface. Make sure that both faces are covered 360 degrees.

Illustration 296 g01988373

2. Install rubber masks to the main journals and pin journals. Use tie straps to secure the rubber masks in place.

Illustration 297 g01988374

3. Center the rubber masks using guide shoes. Remove the guide shoes after masks are centered.

Illustration 298 g01988375

4. Cover the counterweight pads (1 and 16) or (1 and 12) with wide pad covers. Cover the remaining counterweight pads with narrow pad covers. Secure the covers in the center holes with suitable fasteners.

Illustration 299 g01988376

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5. Press rubber plugs firmly into the pin journal cross oil holes to prevent media from entering. Perform this step if the original plugs have been removed.

Illustration 300 g01988377

6. Install covers on the drive and idler ends to prevent the media from contacting the finished surfaces.

Illustration 301 g01988378

7. Install the crankshaft into the shot peening machine. Make sure and remove any lifting devices. Install covers on the remaining counterweight pads. Note: This operation should only be performed by experienced operators. The operators should be trained for the equipment that will be used.

Guidelines for Crankshaft Balancing This section provides a brief overview of crankshaft balancing techniques that are applicable to all crankshafts. More detailed information regarding balancing can be found in the model-specific Reuse and Salvage Guideline Crankshaft Specification manual. If any of the following has been performed, then the crankshaft must be inspected for proper crankshaft balance. Grinding a select number of journal surfaces rather than all the main or all the pin journals. Replacement of counterweight hardware. Machining of crankshaft counterweight pad. Replacement of counterweight. Grinding and polishing the crankshaft has not been shown to alter the crankshaft balance out of factory specifications. If doubt occurs if the crankshaft should be balanced after machining, then check the balance of the crankshaft. Each individual dealership is responsible for acquiring balancing equipment or the service of a reputable balancing company. When machining operations alter the mass unevenly around the axis of rotation, then crankshaft unbalance occurs. Crankshaft unbalance produces vibration which can cause excessive bearing wear, noisy operation, failure of structural parts, and a reduction in overall engine efficiency. Crankshaft balancing must be made dynamically in two planes perpendicular to the rotational axis. Note: The 3508 engine requires custom bob weights for balancing.

Illustration 302

g06174818

Typical crankshaft balancing zones. (A) Zone A (B) Zone B (1) Balancing bore example.

When drilling the balancing bore (1), keep the center line of the bore perpendicular to the axis of rotation. Drilling is only allowed in Zones (A) and (B) of the counterweight to achieve balance specifications listed in Table 32. Reference the model-specific Reuse and Salvage Guideline Specification manual for model-specific zone areas and bore depths. Do not modify any existing balancing holes. If material must be removed to achieve balance, then a new balancing hole must be drilled.

Illustration 303

g06174821

Typical counterweight balancing hole location (C) Minimum sidewall thickness

When drilling a balancing hole, maintain a minimum amount of material on the counterweight for the entire depth of the balance hole. Refer to Illustration 303 for an example. Table 32 identifies balance specifications and sidewall thickness of the balance bore. Table 32 Crankshaft Balancing Specifications Engine Size

Crankshaft Balance All crankshafts spun at 200 RPM

Minimum Hole Sidewall Thickness

C4.4 C6.6 C7 C9 Series 3000 Series 3100

1.5 gm(1) 2.083 oz· inch (2)

1.5 mm (0.06 inch)

Series 3400 C11 C12 C15 C16 C18 C27 C32

1.8 g m 2.50 oz· inch

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C175

3.5 g m 4.861 oz· inch

4.0 mm (0.16 inch)

Series 3500

3.5 g m 4.861 oz· inch

5.0 mm (0.20 inch)

Series 3600 C280

22 g m 30.552 oz· inch

8.0 mm (0.32 inch)

(1)

gm = Gram-Meter is the unit of measure used to describe the amount of unbalance in a rotating body. An unbalance of 1 gm is equivalent to a mass of 1 g rotating at a distance of 1 m from the axis.

(2)

oz·in = Ounce-Inch is the unit of measure used to describe the amount of unbalance in a rotating body. An unbalance of 1oz·inch is equivalent to a mass of 1 oz rotating at a distance of 1 in from the axis.

Clean the Crankshaft after Salvage A ground crankshaft must be cleaned thoroughly before, during, and after the salvage process. Use an air hose to remove coolant, sludge, steel shot, and metal particles from the oil passages. Use the appropriate sized oil passage brush and drill to brush the oil passages clean. Take care not to damage the journals while using the drill. Use the brushes from the rod and the main ends of the journal. The brushes must also be used from the hole for lightening the crankshaft and the plug end. Flush the oil passages with solvent to ensure that there is no debris remaining. Inspect each oil passage with a bore scope to ensure cleanliness.

Proper Crankshaft Seal Handling Best Practices Background To reduce the risk of leaks and failures, it is important that crankshaft seals are properly installed. Proper operation of a crankshaft seal depends on many factors such as: Cleanliness of the seal, tooling, and all other mating components. Appropriate protection and handling of the crankshaft seal. Mating Component Storage Crankshafts and housings should be stored in a manner that will reduce contamination and damage to the sealing surfaces. Mating Component and Tooling Cleanliness The housings, crankshafts, and all installation-related items must be free of all contamination. The housing bores and crankshafts must be free of scratches, nicks, dents, or any other feature that will compromise sealing. Each housing bore and shaft should be wiped clean with a lint-free wipe before installation. Inventory of subassembled crankshaft seals should be minimized to reduce risk of contamination and damage. Handling of Crankshaft Seals Some crankshaft seals arrive with a supplier-applied sealant around the outer diameter of the seal case and/or the inner diameter of the wear sleeve. This coating will typically be red, blue, or green depending on the supplier and seal location. This coating is critical for sealing against the bore and shaft, and must not be scratched or removed from the seal.

Illustration 304

g02860196

Proper crankshaft seal handling.

To avoid contamination, seals should be handled only by touching uncoated metal surfaces whenever possible. To reduce the risk of damage, never touch the seal on the sealing surface. If necessary, seals may be carefully handled on coated metal surfaces. Ensure that the coating does not get scratched nor contaminated.

Illustration 305 g02860461 (1) Wear sleeve (2) Sealing lip

Some seals are supplied with a plastic sleeve around the interior diameter. The sleeve holds the PTFE (Polytetrafluoroethylene) sealing lips in place and the sleeve protects the seals from damage. Once this plastic sleeve has been removed, the PTFE sealing lips will begin to relax. If the PTFE sealing lips relax, the seals will prevent proper installation. These plastic sleeves must only be removed during or immediately before installation. Assembly Tooling Always refer to the appropriate Disassembly and Assembly Manual and/or Special Instruction for the tooling needed to install crankshaft seals for an engine model. Assembly areas should have procedures for inspection and cleaning of seal installation tooling. Areas of special importance include: Any damage to the installation tooling that could damage the crankshaft seal diameter face. Any malfunction of the hydraulic or pneumatic press supply pressure or pressure regulator. The piloting features of the tool must be square and free from damage. Inspect the ram inside the press for damage or excessive wear.

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If any of the above occurs, the seal may be damaged or will not be seated correctly. If damage is observed or noted, then immediately stop using the tool. Notify the appropriate dealer personnel to report the damage. Routine Maintenance - All seal-specific tooling should be placed on a routine maintenance schedule similar to the torque-tooling schedule. Reporting Damage - A formal reporting process shall be established at every dealer to report damaged tooling. Replacement Tooling - Replacement tooling should be in inventory and available for immediate use to reduce the risk of downtime. Tooling storage surfaces will be clean and free from contamination. Preassembly Inspection of Critical Components Complete a brief inspection for seal and mating components for damage and contamination. This inspection is to provide a brief visual review of the part and mating component for damage or debris. This inspection is to help identify part issues before assembling the parts to the components. Complete a visual inspection to verify the presence of the spring in crankshaft lip seals. Note: Not all crankshaft lip seals will contain springs. Before installation of the crankshaft seal and the wear sleeve, inspect the crankshaft for scratches. Also, inspect the crankshaft for any distortion on the surface that may lead to an out of round condition. Use a polishing cloth to remove any slight imperfections on the crankshaft. Assembly Do not lubricate crankshaft seals. Crankshaft seals are intended for dry installation. Neither the sealing lip nor the journal should be lubricated. Apply Loctite sealant to the seal outside diameter and/or the wear sleeve inside diameter if either surface does not have supplier applied coating. Use the correct seal assembly tool as specified in the proper Disassembly and Assembly Manual. Follow the tooling inspection and care processes during assembly. All crankshaft seals require either a wear sleeve or installation sleeve for assembly regardless of the shaft. The sleeve prevents the seal lip from relaxing and being folded under during assembly.

6I-3746 1W-5009 6I-3746 1W-50096I-3746 1W-50096I-37461W-50096I-3746 1W-5009 6I-37461W5009Procedure to Inspect and Salvage the Gear on 1W-5009 and 6I-3746 Crankshaft Assemblies Used in 3408 Engines The 2W-3878 Gear on the crankshafts of some 3408 Engines may be misaligned or incorrectly positioned. This Guideline provides the dimensions and procedures to check the gear's alignment and location.

Fabricated Tooling

Illustration 306

g06283191

Gear installation tool. (1) Plate (2) Ring (3) 0S-1616 Bolt, 1/4-20 x 1 (4) 5P-0537 Washer (5) 1A-4273 Bolt, 5/8-18 x 1 1/4 (6) 5P-8247 Washer. (A) Ground surface

Illustration 307

g06283197

Plate made from SAE 1020 steel

Table 33 Specifications for Plate Callout

Description / Dimensions

(A)

Grind this side flat, after holes have been drilled. A flatness of 0.03 mm (0.00118 inch) must be maintained.

(B)

12.7 ± 1.5 mm (0.50000 ± 0.05906 inch)

(C)

254.0 ± 3.0 mm (9.99998 ± 0.11811 inch)

(D)

76.0 ± 3.0 mm (2.99212 ± 0.11811 inch)

(E)

127.0 ± 3.0 mm (4.99999 ± 0.11811 inch)

(F)

90.0 mm (3.54330 inch)

(G)

66.0 mm (2.59842 inch)

(H)

19.0 mm (0.74803 inch)

(I)

8.0 mm (0.31496 inch) Diameter Holes (4 places)

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

(J)

54.0 mm (2.12598 inch) Diameter Hole

(K)

19.0 mm (0.74803 inch)

Illustration 308

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Ring made from SAE 1020 steel

Table 34 Specifications for Plate Callout

Description / Dimensions

(A)

27.76 ± 0.03 mm (1.09291 ± 0.00118 inch)

(B)

Grind both sides flat after holes have been drilled. A flatness of 0.03 mm (0.00118 inch) must be maintained.

(C)

203.0 ± 0.50 mm (7.99211 ± 0.01969 inch)

(D)

165.1 ± 0.50 mm (6.500 ± 0.01969 inch)

(E)

90.0 mm (3.54330 inch)

(F)

19.0 mm (0.74803 inch)

(G)

1/4 - 20 2B Thread 12.7 mm (0.50000 inch) Deep (4 holes)

The gear installation tool consists of a fabricated plate and ring which are bolted together into an assembly. Illustration 306 shows the assembled installation tool. Illustrations 307 and 308 show the dimensions to manufacture the plate and ring.

Inspection Two variables will be measured with this inspection procedure: 1. The runout of the front crankshaft gear. 2. The depth of the crankshaft gear in relation to the front face of the crankshaft. Procedure 1. Remove the belts, crankshaft pulley, damper, and front crankshaft seal. Note: Refer to the appropriate service manual for the correct tools and procedure for the proper removal of the crankshaft seal.

Illustration 309

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Check dimension (A) using dial indicator or depth micrometer. (A) 26.41 mm (1.03976 inch) minimum to 28.95 mm (1.13976 inch) maximum.

2. Measure the location of the gear in relation to the crankshaft's front face. Use a depth micrometer or a magnetic base and dial indicator, check distance (A) from the front crankshaft face, where the damper contacts the crankshaft to the face of crankshaft gear as shown in Illustration 309.

Illustration 310 g06283210

3. Measure and calculate the runout of the gear a. Make twelve measurements equally spaced across from every hole of the crankshaft face. Table 35 Runout Measurements for Dimensions (A) Location

Measurement Obtained (record the measurements in the blanks)

1 2 3 4 5 6 7 8

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

9 10 11 12 b. Record the measurements in Table 35. c. Calculate the runout of the gear by subtracting the minimum measured distance from the maximum measured distance. 4. If the run out measurement is 0.25 mm (0.00984 inch) or less, and the gear is within the specified dimension (A), the gear alignment is acceptable. Install a new 2W-1733 Seal and a 4W-8089 Damper. 5. If the runout measurement is greater than 0.25 mm (0.00984 inch), the face of the gear is not within the specified dimension ( (A), Illustration 309), or the gear was repositioned previously, replace the gear train and damper assembly using the "Salvage Procedure" in this Guideline.

Salvage Procedure Before starting the salvage procedure, fabricate the gear installation tool as shown in the "Fabricated Tooling" section. Gear Removal This procedure can be completed without removing the engine from the machine. 1. The front gear train must be replaced along with the front crankshaft damper. 2. Pin time the fuel pump and flywheel. 3. Support the front of the engine, with overhead support, before proceeding with disassembly of the front gear train. 4. Drain the sump oil. 5. Remove the oil pan, front main bearing cap, and oil pump. 6. Remove the water pump and lines to allow removal of the front housing. 7. Remove the automatic timing advance cover and front housing. 8. Move the camshaft forward. a. Remove the 3T-5447 Hydraulic Pump and drive from the flywheel housing. b. Remove the rear 2W-8038 Camshaft Gear. 9. Remove valve covers. 10. Using the appropriate tools, pull the push rods and valve lifters out of the way [lifters need to be pulled up approximately 25.0 mm (0.98425 inch) to allow movement of camshaft.

NOTICE Using excessive heat to remove the gear may cause damage to the crankshaft. Do not heat the gear over 204° C (400° F).

11. Remove the crankshaft gear using the 1P-2321 Puller Group. Heat the gear with a torch to ease its removal 12. After removing the crankshaft gear, check the front crankshaft gear journal dimension at four equally spaced locations (12 O'clock, 1:30, 3:00, and 4:30). The measurement should be 158.75 ± 0.03 mm (6.24999 ± 0.00118 inch). If the journal is undersized, the crankshaft may need to be replaced, which requires removal of the engine from the machine. Note: The 2W-3878 Crankshaft Gear should have a bore with an inside diameter of 158.620 ± 0.03 mm (6.24487 ± 0.00118 inch). The interference fit between the gear and the crankshaft should be a minimum of 0.075 mm (0.00295 inch). 13. Remove the camshaft thrust plate bolts to allow the camshaft to slide forward. Slide the camshaft forward no more than 38.0 mm (1.49606 inch). 14. Remove the 6I-3749 Idler and Weight Gear Assembly by removing the four 2B-2695 Bolts. Slide the assembly forward the same distance as the camshaft was moved 15. Remove the five bolts holding the 7N-2484 Idler Drive Shaft to the block. 16. The 6I-3749 Idler and Weight Gear Assembly and drive shaft will now slide sideways away from the camshaft gear Note: The parts book does not show a 6I-3749 Idler and Weight Gear Assembly. This is the parts service gear assembly for 6I-3750 Gear Assembly and 4N-0343 Sleeve Bearing. 17. Remove the 2W-8375 Gear (Oil Pump) and the 100-8178 Gear (Oil Pump Idler). 18. Install a new 2W-3878 Gear onto the crankshaft.

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797F XQ Off-Highway Truck WSP00001-UP (MACHINE) POWERED BY C175-20 Engine(SEBP5926 - 127) - Systems & Components

Gear Installation 1. Heat the crankshaft gear to 204° C (400° F), for one hour before installation.

Illustration 311

g06283523

Install the gear onto shoulder of crankshaft. (A) 3.0 mm (0.11811 inch) (1) Gear slot and alignment dowel pin. (2) Block (3) Crankshaft

2. Install the gear onto the crankshaft journal aligning the slot in the gear with the dowel in the crankshaft. Install the gear 3.0 mm (0.11811 inch) from the shoulder of the crankshaft as shown in Illustration 311. Note: The elapsed time from removal of gear from the heating unit to installation onto the crankshaft should be no more than one minute.

Illustration 312

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Push the gear, using the installation tool, onto the shaft to its final location. (2) Block (3) Crankshaft (4) 1A-4273 Bolt and 5P-8247 Washer

3. Use the fabricated gear installation tool to finish pushing the gear onto the crankshaft to the proper depth as shown in Illustration 312. This must be done before the gear shrinks and locks. 4. Once the plate portion of the tool is against the face of the crankshaft, install and tighten the two bolts. This will hold the tool in place until the gear cools. The gear must be against and flush with the ring of the installation tool. 5. After the gear has cooled, check to make sure the runout of the gear and the depth on the crankshaft is correct. The gear runout should not exceed 25.0 mm (0.98425 inch). 6. Install a new 6I-3749 Gear Assembly (Idler Gear and Bearing Assembly), 100-8178 Gear (Oil Pump Idler), and 2W-3875 Gear (Oil Pump). 7. Slide the camshaft into its correct position and install the valve lifters, push rods, and valve covers. 8. Install the rear camshaft gear, 3T-5447 Hydraulic Pump and Drive, automatic timing advance, timing gear cover, new 2W-1733 Seal, crankshaft pulley, 4W-8089 Damper, belts, front engine support, oil pump, front main bearing cap, and oil pan. Replace the engine oil.

Storage Procedures Proper protection of the crankshaft from corrosion is important. Corrosion will start in as little as one hour after the crankshaft has been cleaned. When the crankshaft will not be inspected for one hour or less the crankshaft should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The crankshaft should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 313. When the crankshaft will not be inspected in two days or more the crankshaft should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the crankshaft. See Illustration 314. Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Illustration 313

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Example of protection for a component that is stored for a shorter term

Illustration 314

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Example of protection for a component that is stored for a longer period Copyright 1993 - 2019 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

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