Reusability Inspection of Well Stimulation Pump Crankshaft {1202, 5070, 6002} Caterpillar

Well Pump

WS223 (S/N: SR31-UP)

WS223 SS (S/N: BM31-UP)

WS223 XD (S/N: SR41-UP)

WS255 (S/N: SR51-UP)

WS255 SS (S/N: BM51-UP)

WS255 XD (S/N: SR61-UP)

WS273 XD (S/N: DG21-UP)

WS305 XD (S/N: EA21-UP)

WSP223 (S/N: FNJ1-UP)

WSP255 (S/N: FNK1-UP)

WSP273 (S/N: DG31-UP)

WSP305 (S/N: EA31-UP)

Introduction

Table 1

Revision	Summary of Changes in M0069554
01	Published Document

© 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 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources 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 does 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

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 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.

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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, ensure 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 well stimulation pump 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, magnetic particle inspection, dimensional specifications, and reconditioning of well stimulation pump 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 stimulation pump conditions that could have caused the need for reconditioning.

References

Reference: Reuse And Salvage Guidelines, SEBF8187, "Standardized Parts Marking Procedures"

Reference: Operation and Maintenance Manual, SEBU9149, "Well Stimulation Pumps"

Reference: Disassembly and Assembly, UENR3290, "WS273 XD, WS305 XD, WSF273 XD, WSF305 XD, WSP273 and WSP305 Well Stimulation Pumps"

Reference: Disassembly and Assembly, UENR6796, "WS223, WS223 SS, WS223 XD, WS255, WS255 SS, WS255 XD, WSP223, WSP255, WSF223, WSF223 SS, WSF223 XD, WSF255, WSF255 SS, and WSF255 XD Well Stimulation Pumps"

Standardized Parts Marking

Reference: Reuse And Salvage Guidelines, SEBF8187, "Standardized Parts Marking Procedures"

Table 2

Required Tools
Part Number	Part Description
9U-7378 through 9U-7387	Paint Markers
9U-7377	Metal Marking Pen
223-1154	Air Engraver

All parts must be thoroughly cleaned and degreased prior to using the 9U-7377Metal Marking Pen . After the part is etched, allow the part to dry for 30 seconds before wiping with a cloth soaked in oil.

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NOTICE
Do not use a number metal stamp set to mark parts. The impact from striking the stamp will cause an abnormal stress riser. The added stress riser may cause premature part failure.

A standardized method for marking components is necessary to be able to account for the history of a rebuilt part. The following information should be recorded: the number of rebuilds and the number of hours on each rebuild the part number of the component. This information will help extend the life of the Planned Component Rebuild (PCR). A longer life of the PCR means a lower cost per hour to operate the vehicles.

Code for Marking Procedure

The procedure for marking includes a code that will identify the number of rebuilds and the number of hours on each rebuild.

Illustration 3	g03885129
Illustration 3 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the component had been rebuilt twice. The second number (10) indicates that there were 10,000 additional hours on the component at the time of rebuild.

Mark all parts according to the examples that follow:

• In "1 - 12", the "1" would indicate the first rebuild, and the "12" would indicate that there were 12,000 hours on the part at the time of rebuild.

• In "2 - 10", the "2" indicates that the piece has already had two rebuilds. The "10" would indicate that there were 10,000 additional hours on the part at the time of the second rebuild.

Procedure for Marking

Illustration 4	g06096793
Example of standardized marking on a typical Cat crankshaft

Crankshafts should be marked on the crankshaft end near the bolt hole pattern. Use a metal marking pen or an air engraver. If an air engraver is used, make sure that there are no raised surfaces around the marked area.

This coding can be used by all dealers and the coding will help with identification at time of rebuild. This marking can be especially helpful if units that have been rebuilt are sold into different territories. As new overhauls are completed, the previous markings should be left on the part. To obtain the total number of hours for the component in Illustration 3, add the first and second rebuild hours. In this example the component has a total of 22,000 hours.

Nomenclature

Illustration 5	g06048830
(1) Oil Bushing Port (2) Crankshaft Hub (3) Bull Gear Mounting Threads (4) Rod Journals (5) Main Journals (6) Snap Ring Grooves (WS223 Only) (7) Fillet (8) Lube Pathway (9) Cheek (10) Keyway

General Information

When a crankshaft is moved, be careful not to damage the journals. Use clean nylon slings with a capacity greater than the weight of the crankshaft.

Put slings into position around the two end shafts. 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 particles.

Prior to Visual Inspection

1. Immediately after a crankshaft has been removed from a pump housing, 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. Clean the crankshaft according to information found within the "Crankshaft Cleaning Procedure" found within this document.

4. Perform a visual inspection of the crankshaft according to the "Crankshaft Visual Inspection" procedure found within this document.

5. Measure the crankshaft according to the "Well Stimulation Pump Crankshaft Specifications" procedure within this document.

Crankshaft Cleaning Procedure

New or remanufactured crankshafts are covered in a rust preventative material. The crankshaft removed from the pump is covered in engine oil, oil is also a rust preventative. Before the crankshaft can be installed in a pump, 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.

General Information

Note: For a new crankshaft, it is necessary to flush all oil passages according to the procedures in this instruction.

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 salvaged. Grinding debris such as metal chips and abrasive material can remain in the oil passages. Therefore the oil passages must be given extra attention when cleaning.

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 wrap 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. The chart that follows gives the part number and size of brushes that are available from the parts department.

Table 3

Brush Part Number	Brush Diameter
6V-7067	6.0 mm (0.25 in)
6V-3182	8.0 mm (0.32 in)
1P-5571	10.0 mm (0.40 in)
6V-3183	11.0 mm (0.43 in)
6V-7091	12.7 mm (0.50 in)
1P-5572	19.1 mm (0.75 in)

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NOTICE
Do not use a brush that has worn or loose bristles. DO NOT use a brush that has metal bristles. Only use a nylon brush for cleaning the internal passages of the crankshaft.

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 works best when between 43° to 66° C (110° 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 Gp 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, and so forth), 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 ensure that all passages are 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.

Crankshaft Cleaning Process

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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.

   Note: Step 2 is not necessary for a new crankshaft.

3. Remove all covers and plugs from the crankshaft lube pathways.

4. Clean the Lube Pathways

   It is important for the lube pathways to be thoroughly cleaned. The lube pathway holes must be cleaned from every possible angle to ensure that the passages are cleaned correctly.
   To ensure that lube pathways are kept free of debris, flush all passages with solvent during the procedure to clean lube pathways. After the lube pathways are thoroughly cleaned, use an air hose to remove the remainder of the solvent.

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

5. Choose the correct size brush for the cleaning procedure, refer to Table . The diameter of the brush must be slightly larger than the diameter of the holes that are to be cleaned.

6. Put the brush in a variable speed drill. Use a petroleum base cleaning solvent. With the brush and electric drill loosen any debris (sludge, carbon deposits, and so forth) in the lube pathway.

7. Where possible, ensure that the end of the brush goes all the way to the end of each lube pathway. Each lube pathway 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.

8. First remove most of the debris using the brush and cleaning solvent. Then 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, then continue the cleaning procedure. Clean especially in those areas that cannot be seen, or where visibility is difficult. Use a vigorous cleaning action with the brush while continuing to flush the passages with the cleaning gun and cleaning solution.

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.

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. The following procedures will provide guidance through the visual inspection process.

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 6	g01396282
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 microweld the two parts 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 microwelded 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 heavy smearing.

Due to the heat involved in the smearing process, it is recommended that the journal hardness measured after removal of smeared material. For procedures to check the hardness and dimensions of the journal, refer to the hardness inspection portion of Reuse and Salvage Guideline, SEBF8054.

Illustration 7	g01396436
Typical example of smearing. Salvage processes can be attempted.

Illustration 8	g01396438
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 is sometimes discolored to a blue/black shade as a result of heat. If little or no discoloration is present, this lack of color change indicates that a significant supply of lube oil prevented extreme temperatures as adhesive wear progressed. Sufficient heat can be generated by adhesive wear to alter the crankshafts heat treatment. When this wear happens, the heat treatment is altered and the crankshaft cannot be salvaged.

Heat damage can affect the hardness of the journal surface. Extra caution must be used if reusing a crankshaft damaged by heat. Only attempt to salvage heat damaged crankshafts if discoloration is minor, if the hardness of the journal is acceptable, and the damage can be removed by polishing. For procedures to check the hardness of the journal, refer to Reuse and Salvage Guideline, SEBF8054.

Illustration 9	g01396286
Journal that shows moderate signs of heat and smeared material Salvage processes can be attempted.

Illustration 10	g01396288
Journals that show signs of significant heat and significant bluing. Salvage processes shouldNOTbe attempted.

Illustration 11	g06096846
Journals that show signs of heat and smeared material Salvage processes can be attempted.

Journals with Dents or Scratches

Circumferential scratching of journal surfaces is a sign of abrasive wear. Journals are heat treated to a high hardness level. Therefore to scratch the journal, abrasive scratching must be caused by even harder particles such as sand, grit blast, or sanding disc particles. Small, fine abrasive particles mixed with oil usually 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 finish, refer to Reuse and Salvage Guideline, SEBF8054.

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 12	g01396295
Example of lightly scratched bearing journals Salvage processes can be attempted.

Illustration 13	g01396296
Example of lightly scratched bearing journals Salvage processes can be attempted.

Illustration 14	g01396299
Example of lightly scratched bearing journals Salvage processes can be attempted.

Illustration 15	g06097142
The journal has a single heavy scratch on the circumference. Salvage 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 polish might be possible.

Illustration 16	g01396313
Small dent on rod journal Salvage processes can be attempted.

Illustration 17	g01396321
Deep scratch on rod bearing journal Salvage processes can be attempted.

Illustrations 16 and 17 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 dent or scratch on a rod journal. For these rod journals, salvage processes can be attempted to restore the journal. After salvage, inspect the rod journal for potential reuse.

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 17 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 finish and magnetic particle inspection. If the journal is not acceptable, then salvage might be possible. After salvaging, the journal must meet the surface profile, surface finish, magnetic particle inspection, and dimensions.

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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.

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 finish of the crankshaft journals. If heavy corrosion is present on the surface of the journals, then the lube pathway must be inspected with a bore scope.

If corrosion is found within the lube pathway, it is not recommended to salvage the crankshaft. If light corrosion is found on the journal surfaces and the lube pathways are clear, then salvage processes can be attempted.

Illustration 18	g01396545
Typical example of corrosion The corrosion has pitted the hardened surface of the journals heavily. Salvage processes shouldNOTbe attempted.

Illustration 19	g01396580
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 20	g01396582
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.

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.

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

Illustration 21	g01397251
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 polishing, then the crankshaft may be salvaged. If pitting remains after polishing, then the crankshaft cannot be reused.

Illustration 22	g01397253
Pitting on a fillet Salvage processes may be attempted.

Illustration 23	g01397290
Fillet with marks from heat Salvage processes may be attempted.

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

Keyway

Illustration 24	g06096779

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

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

Bull Gear Thread Inspection and Salvage

Inspect the Bull Gear Mounting Threads for damage. If the threads are damaged to the point of needing replacement, then it is acceptable to utilize the appropriate Lock-N-Stitch insert. When utilizing a Lock-N-Stitch insert, it is recommended that adjacent holes should not be reworked and do not repair more than half the holes on either end.

Well Stimulation Pump Crankshaft 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. Crankshafts that reached end of life without an issue and have, passed visual inspection, and a magnetic particle inspection can be cleaned and put back to service.

When measuring diameter and taper, one recommended method is to use a bearing half shell and a marker to draw a straight line on the crankshaft journal. Draw three lines approximately 120° apart. Then measure diameter and taper along the lines drawn on the crankshaft journal.

Process to Inspect for Diameter

Illustration 25	g06096614
Snap Gauge tooling for use in measuring Cat crankshafts.

Illustration 26	g06096663
Snap Gauge tooling in use.

The crankshaft must measure within a diameter specification. Caterpillar recommends the use of a Snap Gauge or Air Gauge with a round master ring to inspect for diameter. Measure diameter in at least three locations around the journal to ensure roundness. Illustration 26 demonstrates the use of tooling to inspect diameter. Record the diameter measurements for rod and main journals and compare the measurements taken to the specifications listed in Table 4.

Process to Inspect for Taper

Taper refers to the parallelism of the crankshaft journal. When measuring taper, it is important to measure in a straight line along the length of the crankshaft. Use a marker and bearing half shell to draw a straight line on the bearing journal surface along the width of the journal. This line will be a reference mark. Finally use a Snap Gauge or Air Gauge and measure the diameter along the reference line in at least 4 locations. Those diameters when plotted on graph paper will give a visual reference of parallelism and taper along the journal width. Record those measurements and compare the measurements to the specifications listed in Table 4.

Process to Inspect for Surface Finish

Illustration 27	g06096744
Checking crankshaft journal surface finish.

To measure the journal surface finish, use a 448-3698 Profilometer with a 507-2257 Adapter. Support the profilometer and if needed rotate the probe such that the probe will trace along the length of the crankshaft. Check surface finish in at least 2 separate areas of each journal. Compare the measurements found with the specifications listed within Table 4.

Well Stimulation Pump Crankshaft Specifications

Table 4

Crankshaft Measurement Specifications
Part Number	Nominal Diameter		Taper		Fillet Radius	Hardness	Bearing Journal Surface Finish (Ra)
	Main	Rod	Main	Rod	Rod
WSP223
434-9858	406.43 mm (16.001 in) to 406.45 mm (16.002 in)	184.13 mm (7.249 in) to 184.15 mm (7.250 in)	0.254 mm (0.010 inch) with in 254 mm (10 inch)		6.4 mm (0.25 in)	28 / 32 Rc	Mains: 63 Rods: 16
WSP255
434-9918	406.43 mm (16.001 in) to 406.45 mm (16.002 in)	190.46 mm (7.499 in) to 190.50 mm (7.500 in)	0.254 mm (0.010 inch) with in 254 mm (10 inch)		9.7 mm (0.38 in)	28 / 32 Rc	Mains: 63 Rods: 16
WSP273
434-9992	457.264 mm (18.0025 in) to 457.314 mm (18.0045 in)	196.83 mm (7.749 in) to 196.85 mm (7.750 in)	0.254 mm (0.010 inch) with in 254 mm (10 inch)		12.7 mm (0.5 in)	28 / 32 Rc	Mains: 63 Rods: 16
WSP305
435-0068	457.264 mm (18.0025 in) to 457.314 mm (18.0045 in)	196.83 mm (7.749 in) to 196.85 mm (7.750 in)	0.254 mm (0.010 inch) with in 254 mm (10 inch)		12.7 mm (0.5 in)	28 / 32 Rc	Mains: 63 Rods: 16

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.

Glossary of Terms

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

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 manganese sulfide inclusions is 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 80.

Seam - Usually a long straight defect, found in most instances on the unmachined surface of the crankshaft. These defects 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.

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 28	g02798317
(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 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 removed by grinding or is found in a critical area, then the crankshaft cannot be reused. Refer to the section "Magnetic Particle Inspection" for further guidance.

Illustration 29	g02856559
An example of an open indication with the carrier solution under an ultraviolet light

Illustration 30	g02856561
Illustration 29 without the carrier solution shown under white light.

Illustration 31	g02856563
An example of an open indication with the carrier solution under an ultraviolet light

Illustration 32	g02856566
Illustration 31 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.

Illustration 33	g02898899
An example of a closed indication with the carrier solution under an ultraviolet light.

Illustration 34	g01445452
Illustration 33 without the carrier solution shown under white light.

Illustration 35	g02801576
An example of a closed indication with the carrier solution under an ultraviolet light.

Illustration 36	g02801592
Illustration 36 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 beable to be removed by grinding. Cracks in any other area of the crankshaft are not permitted.

Illustration 37	g01445504
An example of a crack with the carrier solution under an ultraviolet light

Illustration 38	g01445516
Illustration 37 without the carrier solution shown under white light.

Illustration 39	g02898916
Nonrelevant flash line indication due to trim line edge under ultraviolet light

Illustration 40	g01445546
Image 39 as seen under white light.

Some sharp linear indications may appear to be cracks but after further investigation the indication discovered is not an actual crack. Sharp transitions near the flash-line can create non-relevant indications. Refer to Illustrations 39 and 40.

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 41	g02801676
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 42	g02801696
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.

Illustration 43	g02801716
(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 44	g02808000
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 45	g02808041
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: A stringer is an inclusion that has been elongated due to the forging process.

Manganese Sulfide Inclusions

Manganese sulfide inclusions are non-crystalline, soft, elongated inclusions that usually do not affect the integrity of the crankshaft.

Illustration 46	g02809222
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 47	g02809300
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

Illustration 48	g01444296
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 49	g01444412

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

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

Illustration 50	g01444484
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 51	g02808196

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 52	g02808216

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

Illustration 53	g01445423
Inspection Microscope

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Illustration 54	g01444625
Rests for crankshafts

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Illustration 55	g01444634
Crankshaft on rests

1. Use the correct vee blocks and use the rests to ensure that the crankshaft is level.
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   Illustration 56	g01444657
   Rollers

2. The crankshaft must be level for the magnetizing coil can move along the crankshaft. Use proper rollers making rotation possible.
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   Illustration 57	g01444691
   Set up for crankshaft with copper pads

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   Illustration 58	g02898979
   Using a spacer

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   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.

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   Illustration 59	g01444793
   Controls for current

5. Adjust the controls on the machine for the correct longitudinal current.

   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

6. Ensure that the concentration is correct. Thoroughly mix the carrier solution.
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   Illustration 60	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.
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   Illustration 61	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 62	g01444946

9. Switch the current setting to go through the magnetizing coil. Adjust the controls on the machine for the correct coil shot current.

   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 in) 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.

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   Illustration 63	g01445077

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 64	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.
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    Illustration 65	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.

Important Areas of Inspection

Specific areas are shown in different colors according to importance.

Table 6

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 in) or wider than 0.15 mm (0.006 in) permitted.	No cracks allowed.	No cracks allowed.

Fillet Area Inspection

Illustration 66	g06093163
Areas of Inspection. Refer to Table 6. (Red) No cracks allowed. No open indications allowed. (Green) No cracks allowed. Open indications smaller than 28.5 mm (1.12 inch) or wider than 0.15 mm (0.006 inch) permitted. (Orange) No cracks allowed.

Fillet Area Inspection Examples

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

Illustration 67	g01446201
Crack through the fillet area Do not reuse the crankshaft.

Illustration 68	g02899836
Crack through the fillet area Do not reuse the crankshaft.

Illustration 69	g01446214
Crack through the fillet area Do not reuse the crankshaft.

Illustration 70	g01446243
The indication at the junction of the fillet and the journal is a crack. Do not reuse the crankshaft.

Illustration 71	g02899858
Fine fillet cracks Do not reuse the crankshaft.

Illustration 72	g02899881
Fine fillet cracks Do not reuse the crankshaft.

Illustration 73	g01446375
Fine cracks in fillet between two rod journals Do not reuse the crankshaft.

Illustration 74	g02899896
Fine cracks in fillet between two rod journals Do not reuse the crankshaft.

Oil Hole Inspection

Oil Hole Area Inspection Examples

Illustration 75	g01446468
Small crack in oil hole Do not reuse the crankshaft.

Illustration 76	g01446471
Small crack in oil hole Do not reuse the crankshaft.

Illustration 77	g01446624
Fine cracks in the oil hole Do not reuse the crankshaft.

Illustration 78	g01446631
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 in) 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.

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NOTICE
Check the hardness of all the journals after grinding.

Illustration 79	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 80	g01446719
These indications are scratches. The scratches are verified by the position of the indications combined with smooth edges. Reuse the crankshaft.

Illustration 81	g01446757
This indication is very fine and is representative of an inclusion or scratch and not a crack. Reuse the crankshaft.

Illustration 82	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 83	g02856537
Multiple cracks. Do not reuse the crankshaft.

Illustration 84	g01447343
This crack in the journal is connected and cannot be removed by grinding. Do not reuse the crankshaft.

Illustration 85	g01447029
The cracks are caused by heat. Do not reuse unless fully removed.

Illustration 86	g01447036
The cracks are caused by heat. Do not reuse unless fully removed.

Illustration 87	g01447052
The cracks are caused by heat. Do not reuse unless fully removed.

Illustration 88	g01447071
The cracks are caused by heat. Do not reuse unless fully removed.

Illustration 89	g01447147
Larger cracks cannot be removed by grinding. Do not reuse the crankshaft.

Illustration 90	g01447163
Cracks remain after a crankshaft has been ground. Do not reuse the crankshaft.

Illustration 91	g01447189
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.

Illustration 92	g06093160
Areas of Inspection. Refer to Table 6. (Red) No cracks allowed. No open indications allowed. (Green) No cracks allowed. Open indications smaller than 28.5 mm (1.12 inch) or wider than 0.15 mm (0.006 inch) permitted. (Orange) No cracks allowed.

Web Area Inspection Examples

Illustration 93	g02901580

Illustration 94	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 95	g02856539
This crack goes into a machined journal sidewall area. Do not reuse the crankshaft.

Illustration 96	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 97	g01447755
Illustration 96 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 98	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 in) into a machined journal surface. Reuse the crankshaft.

Illustration 99	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 in) into a machined journal surface. Reuse the crankshaft.

Illustration 100	g01447915
The indication was ground out in this large area. Make sure that any sharp edges are smooth. Reuse the crankshaft.

Illustration 101	g01447830
The indication goes into a groove. Grinding revealed this indication was not a crack or a deep forging lap. Reuse the crankshaft.

Illustration 102	g02897550
A closer view of Illustration 101, highlighting the groove and the indication. Reuse the crankshaft.

Illustration 103	g01447798
This indication is not a crack. Reuse the crankshaft.

Illustration 104	g01447811
This indication is not a crack. Reuse the crankshaft.

Illustration 105	g01447547
Crack in the lightening hole area. Do not reuse the crankshaft.

Illustration 106	g01447689
Cracks in the lightening hole area Do not reuse the crankshaft.

Illustrations 107 through 109 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 107	g01448020

Illustration 108	g01448046

Illustration 109	g01448070

Flange, the Shaft, and the Keyway Area Inspection

Illustration 110	g06093156
Areas of Inspection. Refer to Table 6. (Red) No cracks allowed. No open indications allowed. (Green) No cracks allowed. Open indications smaller than 28.5 mm (1.12 inch) or wider than 0.15 mm (0.006 inch) permitted. (Orange) No cracks allowed.

Flange, the Shaft, and the Keyway Area Inspection Examples

Illustration 111	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.

Illustration 112	g02901721
Do not reuse the crankshaft. (3) The gear is located in an area that has a crack.

Suppliers of Magnetic Particle Test Equipment

Note: Manufacturers that follow may not have machines that can hold the larger Cat 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