SEBF8041 - Specifications for Crankshafts in 3500 Engines {0760, 1202}.pdf

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Búsq Búsqu ueda del del med medio - SEB SEBF80 F8041 - Spec Specific ifica ations tions for for Cran Cranksha kshafts fts in 3500 500 Eng Engines ines {0760 {0760,, 1202} 202}

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Bienvenido: r080am5 Producto: NO SE HA ESCOGIDO NINGUN EQUIPO Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO

Pautas de reutilización y recuperación Specifications for Crankshafts in 3500 Engines {0760, 1202} Núm ero de medio -SEB F8041-49

F echa de publicación -21/01/2015

F echa de actualización -02/06/2016

Caterpillar: Confidential Yellow

i06718100

Specifications for Crankshafts in 3500 Engines {0760, 1202} SMCS - 0760; 1202

Engine 3500 and G3500 Engines 3512B (S/N: FFS1-UP) 3516B (S/N: LR41-UP)

Introduction Table 1 Revision

49 46-48

45

43, 44

Summary of Changes in SEBF8041

Added new part number 241-0221 to Table 9. Added new serial number prefixes. Incorporated 3500 specifications from Reuse and Salvage Guidelines, SEBF8156 into document. Added the following information: "Oil Hole Dimensions" "Oil Plug Installation" "Improvements to Crankshafts" "Counterweights" "Balancing 3500 Crankshafts" "Counterweight Installation and Bolt Torque" Added new serial number prefixes.

© 2016 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 intellect ual property l aw. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information in order to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made in order 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering: Caterpillar Dealer Technical Communicator Dealer Solution Network Caterpillar Technical Representative Knowledge Network

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

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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 in order 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, ensure that it is safe for you and for other people to use. 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.

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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 This guideline provides reuse specifications for Cat 3500 engine crankshafts. This guideline is intended to supplement Reuse and Salvage Guideline, SEBF8039, Reuse and Salvage Guideline, SEBF8042 and Reuse and Salvage Guideline, SEBF8054. If a crankshaft meets the specifications that are found in this guideline, the crankshaft can be expected to give normal performance until the next overhaul when the crankshaft is used again in the same application. Crankshafts that are acceptable according to Caterpillar specifications that are published in this document are not necessarily acceptable to some insurance companies and marine groups.

References Reference: Reuse and Salvage Guideline, SEBF8039, "Cleaning and Inspecting Cat Crankshafts".


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Reference: Reuse and Salvage Guideline, SEBF8042, "Procedure for Grinding and Polishing the Crankshaft". Reference: Reuse and Salvage Guideline, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts". Reference: Reuse and Salvage Guideline, SEBF8175, "Procedure to Rebuild Vibration Dampers for 3500 and C175 Family of Engines". Reference: Reuse and Salvage Guideline, SEBF9134, "Procedure to Shot Peen 3512, 3516, and 3524 High Displacement Crankshafts". Reference: Technical Supplement, SELD0077, "Cat Remanufactured Products Guide".

Specifications for Using a Crankshaft "As Is" Note: Prior to measuring the crankshaft, perform a visual inspection and magnetic particle inspection as described in Reuse and Salvage Guideline, SEBF8039. Note: Refer to Reuse and Salvage Guideline, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts" for more information on the procedures and tools that are required to perform crankshaft measurements.

The maximum "Use Again" Total Indicator Runout (TIR) for most used crankshafts without straightening or grinding can be found in Table 2. Do not use the crankshaft "as is" if the TIR is more than the specification that is found in Table 2. 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 2. The crankshaft cannot be used "as is" if the TIR for any of the measurements (1) through (8) in Illustration 3 are more than the specifications in Table 2. If possible, grind the crankshaft to the next standard size and measure the crankshaft again to check if the crankshaft is within specifications. High displacement crankshafts must have the fillets of the journals shot peened if the journals are ground undersize. Refer to Reuse and Salvage Guideline, SEBF9134, "Procedure to Shot Peen 3512, 3516, and 3524 High Displacement Crankshafts" for further information on how to shot peen a 3500 crankshaft.

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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 assembly pilot diameter (6) Straight shaft or tapered shaft (7) Flange face for pulley or damper (8) Pilot hub for damper

Table 2 Measurements of the Maximum TIR 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

Flywheel Pilot Outer Diameter (1)

Flange Face for Flywheel (2)

Flywheel Flange Outer Diameter (3)

Main Bearing Journals (4)

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

Straight shaft or Tapered Shaft (6)

Flange Face for Damper or Adapter (7)

Pilot Hub Outer Diameter for Damper (8)

0.05 mm (0.002 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

3508 170.0 mm (6.69 inch)

152-7625 152-4994 7E-4899 7E-3912 7W-0210 9Y-3798

0.025 mm (0.0010 inch)

0.025 mm (0.0010 inch)

0.05 mm (0.002 in.)

0.13 mm (0.005 in.)

0.05 mm (0.002 in.)

3512 170.0 mm (6.69 in.)


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0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.13 mm (0.005 in.)

0.05 mm (0.002 in.)

0.05 mm (0.002 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.) n

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

3512 3524 High Displacement 170.0 mm (6.69 in.)

172-0926 201-4250 354-2977

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.13 mm (0.005 in.)

0.05 mm (0.002 in.)

3516 170.0 mm (6.69 in.)

7E-3916 7E-5165 7W-0218 8N-9700 128-6788 347-0966448-8942 506-1983

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.13 mm (0.005 in.)

0.05 mm (0.002 in.)

3516 High Displacement 170.0 mm (6.69 in.)

172-0830 172-0916 160-5916

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.13 mm (0.005 in.)

0.05 mm (0.002 in.)

3520 170.0 mm (6.69 in.)

315-1391 140-1164 245-1336 322-9885 351-9210

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

0.05 mm (0.002 in.)

0.13 mm (0.005 in.)

0.05 mm (0.002 in.)

Specifications for Straightening a Crankshaft Note: Refer to Reuse and Salvage Guideline, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts" for more information on the procedures and tools that are required to perform crankshaft measurements.

The maximum TIR for straightening Caterpillar crankshafts is found in Table 3. If the TIR for any of the measurements that follow is more than the specifications shown in Table 3, 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 2. Table 3 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 Reuse and Salvage Guideline, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts". Fillet Processing Part Number

Center Main Maximum TIR for Straightening a Crankshaft Indu Induct ctio ion n Hard Harden ened ed

Shot Shot Peen Peenin ing g

NA

None

3508 170.0 mm (6.69 in.) (60° V-8)

7E-4899 7E-3912 7W-0210 9Y-3798 152-4994 152-7625

2.03 mm (0.080 in.)

3512 170.0 mm (6.69 in.) (60° V-12)

1W-5001 7W-0214


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8N-7105 128-6786 161-2512 173-1812 322-9879

2.54 mm (0.100 in.)

All Fillets

None

All Fillets

All Fillets

All Fillets

None

All Fillets

All Fillets

All Fillets

NA

3512 3524 High Displacement 170.0 mm (6.69 in.) (60° V-12)

172-0926 201-4250 354-2977

2.54 mm (0.100 in.) 3516 170.0 mm (6.69 in.) (60° V-16)

7E-3916 7E-5165 7W-0218 8N-9700 128-6788 347-0966 506-1983

3.05 mm (0.120 in.)

3516 High Displacement 170.0 mm (6.69 in.) (60° V-16)

172-0830 172-0916 160-5916

3.05 mm (0.120 in.) 3520 170.0 mm (6.69 in.)

315-1391 140-1164 245-1336 322-9885

3.05 mm (0.120 in.)

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 finish, hardness, out of round, diameter, or taper.

Specification for Surface Finish The maximum permissible surface roughness for bearing journals is given in Table 4. If the journals are rougher than the specification, the journals must be polished. Refer to Reuse and Salvage Guideline, SEBF8042, "Procedure for Grinding and Polishing the Crankshaft" for polishing and grinding procedures. The surface finish of the thrust face must be at least 0.45 micrometers (18 microin.es). Ensure that there are no wear steps on the surface or marks from grinding on the surface. Refer to Reuse and Salvage Guideline, SEBF8039, "Cleaning and Inspecting Cat Crankshafts" for information regarding criteria for inspecting crankshafts.

Specification for Out of Round and Diameter


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

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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 4 demonstrates some various locations to measure diameter. These measurements verify the crankshaft is within diameter and out of round tolerance. The minimum allowable diameter of a rod journal or main journal are shown in Table 4. The out of round tolerance has two dimensions, within 20° of the oil hole and everywhere else. Refer to Illustration 5 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 in.). When measuring outside of that zone the diametrical tolerance is 0.0152 mm (0.00060 in.). For example, if the average journal diameter measures 160.01 mm (6.30 in.), then all measured points will have to be within 160.0024 mm (6.29929 in.) and 160.0227 mm (6.3001 in.) to meet the roundness specification. Two rod journals can measure 0.005 mm (0.0002 in.) under the minimum diameter specifications that are shown in Table 4.

Specification for Taper


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

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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 4.

Specification for Wear on the Thrust Face


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

The measurement between the thrust faces must be within the specifications that are found in Table 4. The thrust faces must begroundverylightly. The faces should be ground approximately between 0.02 mm (0.001 in.) and 0.05 mm (0.002 in.) to clean up damaged surfaces. Refer to the explanation of footnote 3 in Table 4. Thrust faces must have a surface finish of 0.45 micrometers (18 microin.es) or less after being polished.

Specification for Radii of the Fillet for the Journal


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Fillet locations (11) Main journal fillet (12) Rod journal fillet

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. Refer to Reuse and Salvage Guideline, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts" for more information on the procedures and the tools that are required to check the radius of the fillet. If the radius does not meet the specifications that are shown in Table 4, do not use the crankshaft again. Note: The dimensions of the radius that are given in Table 4 are before the procedure of shot peening. When possible, measure the fillets before the procedure of shot peening. Refer t o Reuse and Salvage Guideline, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts" for more information.

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 hardness readings must be within the tolerances that are shown in Table 4. 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 t he 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 4. Table 4 Crankshaft Measurement Specifications

Nominal Diameter

Radius(2) Illustration 9

Taper Taper Thrust Face(1) Illustration 8

Part Number Main

Rod

Main

Rod

Hardness of Br Journal(3) Jour Measured Sur by using Fin. the Shore scale

Main

Ro Rod

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

64 to 69

0.1 (5)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

56 to 64

0.1 (5)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

60 to 68

0.1 (5)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

56 to 64

0.1 (5)

3508 170.0 mm (6.69 in.)

152-7625 152-4994 7E-4899 7E-3912 7W-0210 9Y-3798

160.000 ± 0.025 mm (6.2992 ± 0.0010 in.)

135.000 ± 0.025 mm (5.3150 ± 0.0010 in.)

0.03 mm (0.001 in.)

0.03 mm (0.001 in.)

72.00 ± 0.10 mm (2.835 ± 0.004 in.)

3512 170.0 mm (6.69 in.)

1W-5001 7W-0214 8N-7105 128-6786 161-2512 173-1812 322-9879

160.000 ± 0.025 mm (6.2992 ± 0.0010 in.)

135.000 ± 0.025 mm (5.3150 ± 0.0010 in.)

0.03 mm (0.001 in.)

0.03 mm (0.001 in.)

72.00 ± 0.10 mm (2.835 ± 0.004 in.)

3512 3524 High Displacement 170.0 mm (6.69 in.)

172-0926 201-4250 354-2977

160.00 ± .025 mm (6.299 ± 0.001 in.)

135.000 ± 0.025 mm (5.3150 ± 0.0010 in.)

0.03 mm (0.001 in.)

0.03 mm (0.001 in.)

72.00 ± 0.10 mm (2.835 ± 0.004 in.)

3516 170.0 mm (6.69 in.)

7E-3916 7E-5165 7W-0218 8N-9700 128-6788 347-0966 506-1983

160.00 ± .025 mm (6.299 ± 0.001 in.)

135.000 ± 0.025 mm (5.3150 ± 0.0010 in.)

0.03 mm (0.001 in.)

0.03 mm (0.001 in.)

72.00 ± 0.10 mm (2.835 ± 0.004 in.)

3516


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Búsq Búsqu ueda del del med medio - SEB SEBF80 F8041 - Spec Specific ifica ations tions for for Cran Cranksha kshafts fts in 3500 500 Eng Engines ines {0760 {0760,, 1202} 202} High Displacement 170.0 mm (6.69 in.)

172-0830 172-0916 160-5916

160.00 ± .025 mm (6.299 ± 0.001 in.)

135.000 ± 0.025 mm (5.3150 ± 0.0010 in.)

0.03 mm (0.001 in.)

0.03 mm (0.001 in.)

72.00 ± 0.10 mm (2.835 ± 0.004 in.)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

60 to 68

0.1 (5)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

7.00 ± 0.25 mm (0.276 ± 0.010 in.)

56 to 64

0.1 (5)

3520 170.0 mm (6.69 in.)

315-1391 140-1164 245-1336 322-9885

160.00 ± .025 mm (6.299 ± 0.001 in.)

135.000 ± 0.025 mm (5.3150 ± 0.0010 in.)

0.03 mm (0.001 in.)

0.03 mm (0.001 in.)

72.00 ± 0.10 mm (2.835 ± 0.004 in.)

(1) The maximum width of the thrust face can be up to 0.08 mm (0.003 in.) 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 because the crankshaft will be damaged. (4) Dimensions are i n micrometers (microinches). (microinches).

Grinding Specifications for Crankshafts The following information explains some of the items in Table 5.

Width The width measurement 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 Illustrations 10 through 13 for examples on where to measure journal width. Refer to Table 4 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 in order to ensure that the part numbers a re available before beginning to grind. Subtract t he "undersize" dimension from the dimension in the "diameter" column in Table 4 in order 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 are Cat Remanufactured Crankshafts and have already been ground. For a complete list of available remanufactured crankshafts, refer to the section on crankshafts in the Technical Supplement, SELD0077, "Cat Remanufactured Products Guide".

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Main Bearing Width (13)

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Thrust Bearing Width (14)


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Connecting Rod Bearing Width (15) with offset journals


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Typical example of a 3500 crankshaft with shared connecting rod journals Table 5 Grinding Specifications for Cat Crankshafts

Part Number

Stroke

Main Journals Width Main No. Illustration s10 and 11

Connecting Rod Journals Width Illustrations 12 and 13

Undersize Bearing

3508 170.0 mm (6.69 in.)

152-7625 152-4994 7E-4899 7E-3912 7W-0210 9Y-3798

190.0 mm (7.48 in.)

73.8 mm (2.906 in.) Max

1,2,4,5

72 ± 0.1 mm (2.835 ± 0.004 in.)

3 Thrust Bearing

136.00 + 0.18 mm − 0.08 mm (5.354 + 0.007 in. − 0.003 in.)

0.635 mm (0.0250 in.)

1.27 mm (0.050 in.)

136.00 ± 0.18 mm (5.354 ± 0.007 in.)

0.635 mm (0.0250 in.)

1.27 mm (0.050 in.)

136.00 ± 0.18 mm (5.354 ± 0.007 in.)

0.635 mm (0.0250 in.)

1.27 mm (0.050 in.)

136.00 ± 0.18 mm (5.354 ± 0.007 in.)

0.635 mm (0.0250 in.)

1.27 mm (0.050 in.)

3512 170.0 mm (6.69 in.)

1W-5001 7W-0214 8N-7105 128-6786 161-2512 173-1812 322-9879

190.0 mm (7.48 in.)

73.8 mm (2.906 in.) Max

1,2,3,5,6,7

72 ± 0.1 mm (2.835 ± 0.004 in.)

4 Thrust Bearing 3512 3524 High Displacement 170.0 mm (6.69 in.)

172-0926 201-4250 354-2977

215.0 mm (8.46 in.)

73.8 mm (2.906 in.) Max

1,2,3,5,6,7

72 ± 0.1 mm (2.835 ± 0.004 in.)

4 Thrust Bearing 3516 170.0 mm (6.69 in.)

7E-3916 7E-5165 7W-0218 8N-9700 128-6788 347-0966 506-1983

190.0 mm (7.48 in.)

73.8 mm (2.906 in.) Max

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

72 ± 0.1 mm (2.835 ± 0.004 in.)

5 Thrust Bearing


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Búsq Búsqu ueda del del med medio - SEB SEBF80 F8041 - Spec Specific ifica ations tions for for Cran Cranksha kshafts fts in 3500 500 Eng Engines ines {0760 {0760,, 1202} 202} 3516 High Displacement 170.0 mm (6.69 in.)

172-0830 172-0916 160-5916

215.0 mm (8.46 in.)

73.8 mm (2.906 in.) Max

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

72 ± 0.1 mm (2.835 ± 0.004 in.)

5 Thrust Bearing

136.00 ± 0.18 mm (5.354 ± 0.007 in.)

0.635 mm (0.0250 in.)

1.27 mm (0.050 in.)

136.00 ± 0.18 mm (5.354 ± 0.007 in.)

0.635 mm (0.0250 in.)

1.27 mm (0.050 in.)

G3520 170.0 mm (6.69 in.)

315-1391 140-1164 245-1336 322-9885

190.0 mm (7.48 in.)

72 ± 0.1 mm (2.835 ± 0.004 in.)

11 Thrust Bearing

73.8 mm (2.906 in.) Max

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

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. Refer to Reuse And Salvage Guidelines, SEBF8039 for further guidance on oil hole inspection. 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 14 and 15 are for general reference only.


g 0 37 2 3 3 3 9

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


g 0 37 2 3 6 6 9

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

Oil Plug Installation Installation of the 2W-2288 Plugs should be one of the last assembly procedures performed prior to installation.


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1. Inspect all of 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 6 New Crankshaft Assemblies New Crankshaft

Ground Crankshaft (1)

Upgrade to New Crankshaft(2)

Radius of the Counterweight

Former Crank Assembly

3508

153-3928

0R-5952

0R-2539

222.00 mm (8.74 in.)

9Y-3798 7E-4899

-

0R-7771

-

225.00 mm (8.858 in.)

7W-0210

152-4994

0R-6060

0R-3009

225.00 mm (8.858 in.)

7E-3912-

3512

153-6508

0R-5436

0R-2540

222.00 mm (8.74 in.)

7W-0214 7E-4897

128-6786

0R-6059

0R-3010

225.00 mm (8.858 in.)

- 7E-3914

172-0926

0R-7767

0R-9739

225.00 mm (8.858 in.)

-

3516

448-8940

0R-0788

0R-9737

225.00 mm (8.858 in.)

128-6788

448-8942

10R-0576

0R-9738

225.00 mm (8.858 in.)

347-0966

(1) The crankshaft is ground to 0.635 mm (0.0250 in.) 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 in.) 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 7. Table 7 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 ehicul ar

97-Y672

51-Y602

Generator Set

23Z-2819

24Z-2939

Generator Set (Low Speed)

70-Z722

67-Z734

Spark Ignited

-

4K-C144

Locomotive

-

-

1Z-F518

3Y-F408 3Y-F408

Generator Set

Improvements to 3516 Crankshafts


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g 0 37 0 9 9 1 2

(H) Traditional 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 given in Reuse and Salvage Guideline, SEBF8039, 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 used and a balance check must be performed. 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 in.). Current counterweights in all 3500 engines are made from forged steel. Counterweights are available in the 222.0 mm (8.74 in.) outside radius and in the 225.0 mm (8.86 in.) radius. All counterweights are replaced with forged steel counterweights when the crankshaft is reconditioned. Cylinder blocks have also been changed in order to provide additional clearance for the counterweights with a larger radius.

NOTICE Crankshaft assemblies with the 225.0 mm (8.86 in.) radius that listed in Table 6 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. Refer to Reuse and Salvage Guidelines, SEBF8039 for counterweight visual inspection guidance.

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 8 shows the number of counterweights per crankshaft and the number sequence for the counterweight that is associated with each crankshaft. Table 8 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


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Búsq Búsqu ueda del del med medio - SEB SEBF80 F8041 - Spec Specific ifica ations tions for for Cran Cranksha kshafts fts in 3500 500 Eng Engines ines {0760 {0760,, 1202} 202} 16

16

1 to 16

20

20

1 to 20


g 01 2 5 7 3 23

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


g 01 2 5 7 3 44

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

Illustration 17 shows the former numbering sequence. Illustration 18 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.


g 0 12 5 7 3 6 5

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


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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 19. 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.


g 0 37 8 0 0 6 7

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 20. 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 20. 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. 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


g 0 37 7 8 9 4 4

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 21 for surface finish specifications and area to measure flatness. Pitting


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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. Refer to Reuse and Salvage Guidelines, SEBF8039 for mounting pad visual inspection guidance. Burrs or raised material can be removed from the mounting pad by using a 30.0 mm (1.2 in.) 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. Flatness

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 21. The mounting pad flatness for 3500 engines must be within 0.038 mm (0.0015 in.). Minimum Height of Counterweight Mounting Pad


g 03 7 8 0 11 2

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

Refer to Illustration 22. 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 in.). 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 Counterweight Mounting Pad Inspection

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.


g0 3 7 8 0 13 6

3508 Counterweight Mounting Pad inspection illustrating excess width.

The most accurate inspection is to use the gauge found in REHS9218. Illustration 23 is an example of a 3508 counterweight pad being inspected using a shop made gauge as shown in REHS9218. Refer to Special Instruction, REHS9218, "Crankshaft Rework Procedure for Certain 3508 Off-Highway Truck Engines" for further inspection


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guidance .


g 0 37 8 1 3 5 3

Interference marks on 3508 counterweight mounting pad.


g 0 3 7 8 1 35 4

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 24 and 25 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.


g 0 37 8 0 4 8 1

Measure the counter bore diameter to determine the washer size.


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(H) Counter bore diameter

Before ordering new bolts and washers, first determine the size of the washer. If dimension (H) in Illustration 26 measures 32.5 mm (1.28 in.), use the 128-4845 Bolt Assembly. If the hole measures 27.0 mm (1.06 in.), 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 as well as the bolt head.

If one bolt fails, then the counterweight should be removed and both sides of the joint (the counterweight and counterweight pad) carefully inspected. Refer to Reuse And Salvage Guidelines, SEBF8039 for additional guidance on counterweight and counterweight pad inspection. 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 g·m 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 27 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 g·m at 200 RPM.


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g 0 2 6 90 6 9 6

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 g.m. Hole depth in Zone (A) must not exceed 48 mm (1.89 in.). 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 in.) to drill balancing holes. 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 9 Weights of the bobweights for 3508 series crankshafts Crankshaft Part Number

Weight of Bobweight

152-7625

16.3 kg (35.94 lb)

241-0221

16.3 kg (35.94 lb)

152-4994

15.7 kg (34.61 lb)

7E-4899

15.7 kg (34.61 lb)

7E-3912

15.7 kg (34.61 lb)

7W-0210

15.57 kg (34.326 lb)

9Y-3798

15.57 kg (34.326 lb)

The 3508 B has counterweights with trimmed ears in the #1, #3, #6 and #8 counterweight locations. The #2 and #4 counterweight 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 28 through 31. After trimming, then ensure 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 27.


g 0 37 4 9 4 7 1

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


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g 0 37 4 9 9 3 4

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


g 0 3 7 5 111 9

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


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g 0 37 5 1 2 6 5

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

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.


g 0 37 4 9 8 1 7

3516 number 16 counterweight.

Drill as necessary in Zone (A) so that dynamic unbalance in Planes (J) and (K) in Illustrations 27 and 32 does not exceed 3.5 g.m. Hole depth in Zone (A) must not exceed 48 mm (1.89 in.). 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 in.) to drill balancing holes.

Counterweight Installation and Bolt Torque https://sis.cat. https://sis.cat.com/sisweb/sisweb/tech com/sisweb/sisweb/techdoc/ doc/tech techdoc_ doc_print_p print_page age.jsp?retu .jsp?returnurl= rnurl=/sisweb/sisweb/mediase /sisweb/sisweb/mediasearch/mediah arch/mediahea eaderinfof derinfoframeset.jsp& rameset.jsp&calledpa calledpage=/siswe… ge=/siswe…

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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. Copyright 1993 - 2016 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS.

Wed Oct 19 2016 17:15:44 GMT-0500 (Hora est. Pacífico, Sudamérica) r080am5


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SEBF8041 - Specifications for Crankshafts in 3500 Engines {0760, 1202}.pdf

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