Usage:
Introduction
When a new or remanufactured crankshaft is sent from the Parts Department it will have a rust preventative material covering the complete crankshaft. Before the crankshaft can be installed in an engine it must be thoroughly cleaned according to the procedure given in this instruction.
This cleaning procedure is necessary to remove all of the rust preventative material and to clean all oil passages. After the cleaning procedure has been completed, install a plug in the hole at the side of each connecting rod journal.
Do not perform any procedure, outlined in this publication or order any parts until you read and understand the information contained within.
Reference: Parts Book, Service Manual
General Information
NOTE: For a new or remanufactured crankshaft, it is not necessary to remove the threaded plugs or core plugs that are at the side of the connecting rod journals. It is necessary to flush all oil passages according to the procedures in this instruction.
If an original crankshaft is to be used again in an engine rebuild procedure, then the oil plugs must be replaced with new oil plugs. Remove and discard all of the original oil plugs from the crankshaft and give the crankshaft and the oil passages a complete and thorough cleaning.
Carbon deposits or sludge not removed from the oil passages of a crankshaft can cause bearing failure. Metal chips or other abrasive material not removed from the oil passages can also cause bearing failure.
Always use the procedure shown in this instruction to completely clean the crankshaft before it is installed in an engine.
- * It is especially important to clean crankshafts that have been reground; no grinding debris must remain in the oil passages.
Brushes for Cleaning Procedure
Good quality brushes are necessary to do the cleaning procedure. The chart that follows gives the part number and size of brushes that are available from the parts department. These brushes all have stiff nylon bristles.
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Do not use a brush that has worn or loose bristles. DO NOT use a brush that has metal bristles. Metal bristles that break off and are not removed can cause damage to the bearings, crankshaft and/or other engine parts. |
Flushing (Cleaning) Tools
Crankshaft oil passages usually cannot be cleaned correctly or completely when only a high pressure wash, or a high pressure nozzle, is used to do the cleaning procedure. A nozzle that has an aerated (air assisted) liquid flow for cleaning is recommended.
Use a 2 to 3 percent (by volume) alkaline cleaning solution (detergent) with the cleaning gun. Temperature of the cleaning solution must be 43 to 66° C (110 to 150° F). When connecting the cleaning gun, the recommendation is to install a pump that is 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 8J8850 Filter Group [with 8J1600 Filter Assembly]) can be installed as a filter for the cleaning solution).
NOTE: To do the cleaning procedure, first clean all oil passages thoroughly with the correct brush size. To remove debris (sludge, metal chips, etc.), use the cleaning gun with the cleaning solution to flush (wash out) each oil passage.
Use a flashlight and/or bore scope to inspect each passage and make sure they are all clean. If the cleaning procedure is not done completely and thoroughly, it can cause debris in the crankshaft oil passages to loosen and cause problems after the engine is rebuilt and put into operation.
Crankshaft Cleaning Procedure
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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. |
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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 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 3 is not necessary for a new or remanufactured crankshaft.
3. Remove all covers and plugs from the crankshaft oil passages. For those crankshafts (1) that have plugs similar to plug (2) at the side of the connecting rod journals, or in the lightening holes, it may be necessary to drill out the plugs, then use an "Easy Out Remover" for plug removal. Refer to Guideline for Reusable Parts, Form SEBF8043, entitled Visual Inspection of Crankshafts.
NOTE: If the crankshaft has a core plug in each lightening hole, see the specific Service Manual for core plug removal procedure, or, see the information given in Guideline for Reusable Parts, Form SEBF8043.
4. Choose the correct size brush for the cleaning procedure. The diameter of the brush must be slightly larger than the diameter of the holes that are to be cleaned.
NOTE: New or remanufactured crankshafts that have protective plugs in the oil passage holes will require little or no brushing of the specific oil passage.
5. Put the brush in a variable speed electric drill. Use a petroleum base cleaning solvent, with the brush and electric drill, to loosen any debris (sludge, carbon deposits, etc.) in the oil passages.
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Do not operate the electric drill unless the end of the brush is in the oil passage. This is especially important because crankshaft journals can be damaged by the metal end of the brush. Operate the electric drill at approximately 300 RPM. |
6. Where possible, make sure the end of the brush goes all the way to the end of each oil passage. Each oil passage must be cleaned from every possible direction. Clean all cross-drilled holes (holes that intersect) especially at hole ends. Clean these holes from both directions.
7. When most of the debris has been removed using the brush and cleaning solvent, use a cleaning solution of detergent and water with the brush to remove all debris that can be seen.
After all visible debris has been removed and flushed away, continue the cleaning procedure, especially in those areas that cannot be seen, or where it is difficult to see. Use a vigorous cleaning action with the brush while continuing to flush the passages with the cleaning gun and cleaning solution.
8. For those crankshafts (1) that use a threaded plug (2) in the hole at the side of each connecting rod journal, inspect the threads in these holes. If any of the threads are damaged or have burrs, use the correct size thread tap to clean or repair the threads. Again clean the plug hole and threads with the brush and cleaning solution.
9. For those crankshafts that use a threaded plug at the side of each connecting rod journal, use the chart and illustration above to find the correct plug. Normally with new or remanufactured crankshafts, the plugs are sent in a package with each crankshaft. If necessary, check the Parts Book to be sure of the plug part number and quantity.
NOTE: Do not use a plug if it is damaged or has burrs. Inspect each plug and remove all burrs before installation.
10. Install the correct part number plug (2) in each hole at the side of a connecting rod journal; see detail (A) above. Top surface (B) of each plug (2) must be a minimum of two threads below the bottom of the counter bore as shown.
11. Tighten each plug to its correct installation torque. If the crankshaft has 9F2247 or 7H3171 Plugs, "stake" the crankshaft at one location at the side of each plug hole, see location (C), to hold the plug in position. To "stake" the crankshaft, use a center punch and hammer to move the metal from near the plug hole, so it goes over the top of the plug.
NOTE: The 2W2288 Plug and 5P3476 Plug are self locking plugs so it is not necessary to do the "staking" procedure. It is necessary though, to make sure that these plugs are tightened to their correct installation torque.
12. If the crankshaft uses core plugs and snap rings in the lightening holes, install the necessary core plugs and snap rings. Make sure the snap ring is correctly seated in the snap ring groove.
13. After the plugs have been installed, again flush all crankshaft oil passages with the detergent and water cleaning solution to wash out any metal particles caused during plug installation.
14. Use clean water (no detergent) under pressure to flush the remainder of the cleaning solution from the oil passages; then use air pressure to dry the crankshaft. (Do not let the crankshaft surface dry by evaporation).
NOTE: Put a coat of clean engine oil on the crankshaft to prevent rust damage.
15. If the crankshaft is not to be installed immediately, flush the oil passages with clean oil and put plastic plugs in all oil passage openings. Put a rust inhibitor over the complete crankshaft to prevent damage. The recommendation is to use VCI (Volatile Corrosion Inhibitor) storage bags if the storage period is to be for more than thirty days.
NOTE: For more information about rust inhibitor materials, contact the local Caterpillar Dealer.
16. Before using a stored crankshaft, be sure to remove the rust inhibitor and all plastic plugs. Clean the crankshaft as necessary with the detergent and water solution to remove all evidence of the rust inhibitor. Be sure to flush the crankshaft with pressure water; then dry it and lubricate it as necessary before installation.