Caterpillar Crankshaft Workstation Tool Operating Manual - PDF DOWNLOAD

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TOOL OPERATING MANUAL Using the Crankshaft Workstation SMCS: 0684

NEHS0956 February 2006

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Important Safety Information

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 warnings in this publication and on the product are, therefore, not all-inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

Think Safety 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.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. 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 and most current information before you start any job.

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.

WARNING When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

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.

Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”.

The Safety Alert “WARNING” label is shown below.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

2

Maintenance Section Filter Service . . . . . . . . . . . . . . . . . . . . . . . 26 Mesh Filter . . . . . . . . . . . . . . . . . . . . . . . . 27 Filter Elements . . . . . . . . . . . . . . . . . . . . . 28 Solvent Replacement. . . . . . . . . . . . . . . . . 28 Workstation Collection Tray . . . . . . . . . . . . 30 Other Maintenance . . . . . . . . . . . . . . . . . . 31

Contents Literature Information Section . . . . . . . . . . . . 4 Safety Section . . . . . . . . . . . . . . . . . . . . . . . 4 General Information Section . . . . . . . . . . . . 4 Assembly Section . . . . . . . . . . . . . . . . . . . . 4 Operation Section . . . . . . . . . . . . . . . . . . . . 4 Maintenance Section . . . . . . . . . . . . . . . . . . 4 Safety Section Safety Icon Nomenclature . . . . . . . . . . . . . . 5 Personal Protection/Important Information. . 5 Prohibited Action . . . . . . . . . . . . . . . . . . . . 5 Hazard Avoidance . . . . . . . . . . . . . . . . . . . 5 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . 5 Personal Protection . . . . . . . . . . . . . . . . . . 5 Hazard Avoidance . . . . . . . . . . . . . . . . . . . 6 Pressure Air . . . . . . . . . . . . . . . . . . . . . . . . 6 Entanglement . . . . . . . . . . . . . . . . . . . . . . . 6 General Information Section General Information . . . . . . . . . . . . . . . . . . 7 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 8 Consumable Parts . . . . . . . . . . . . . . . . . . . . 8 Specifications. . . . . . . . . . . . . . . . . . . . . . . . 9 Specifications for Crankshaft Workstation . . 9 Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . 9 References. . . . . . . . . . . . . . . . . . . . . . . . . . 9 Additional Contact Information . . . . . . . . . . 9 Assembly Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Operation Section Operating Controls . . . . . . . . . . . . . . . . . . 13 Install Crankshaft in V-Blocks . . . . . . . . . . 15 Install Crankshaft in Chuck Jaws. . . . . . . . 17 General Wash . . . . . . . . . . . . . . . . . . . . . . 20 Checking Crankshaft Straightness . . . . . . 22 Polishing Crankshaft Journals . . . . . . . . . . 24

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Literature Information Section

Operation Section

This manual should be stored with the tool group.

The Operation section is a reference for the new operator and a refresher for the experienced operator.

This manual contains safety information, operation instructions, and maintenance information.

Photographs and illustrations guide the operator through the correct procedures for using the tool group.

Some photographs or illustrations in this publication show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and its capabilities.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Maintenance Section The Maintenance section is a guide to equipment care.

Whenever a question arises regarding your service tool or this publication, please consult Dealer Service Tools (DST) for the latest available information.

Safety Section The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section The General Information section describes tooling functions and features. It provides useful information on individual parts, additional tooling, and resources.

Assembly Section The Assembly section is a guide to basic set-up of the crankshaft workstation and solvent sump.

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Safety Section

Pressurized air hazard

Safety Icon Nomenclature Protective guards

Personal Protection/Important Information

Safety alert symbol

Read the manual Slipping hazard M DS SD MS DS MS SDS S M

Material safety data sheet Tripping hazard Eye protection Face protection

Safety Warnings Personal Protection

Foot protection

WARNING

Hand protection

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools.

Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

Prohibited Action No loose clothing No smoking

Hazard Avoidance Crushing hazard (foot) Crushing hazard (hand)

To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools.

No smoking Electrical hazard

To avoid eye injury, always wear protective glasses or face shield when solvent is used for cleaning. Make sure no one can be injured by liquids or flying debris when using the crankshaft workstation.

Fire hazard High voltage hazard

5

Hazard Avoidance

WARNING

WARNING

To avoid exposure to s t r o n g chemicals, always wear protective glasses or face shield and protective clothing when servicing filters or replacing solvent.

Clean up all leaked or spilled fluids immediately.

Oil, fuel, or solvent leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area, and clean up all spilled fluids immediately.

Some components of the crankshaft workstation weigh enough to cause crushing injury if dropped.

Always wear protective shoes, and use care when handling heavy components during assembly.

Always consult the Material Safety Data Sheet for chemical hazards and first aid instructions. These sheets should be available from the manufacturer/supplier of the fluid.

Pressure Air

MS SD M SSS DDD M SSS M

WARNING

Always follow the MSS SD M SSS SDDD M S c h e m i c a l M manufacturers instructions for proper handling of solvent. If petroleumbased solvent is used, it must have a flash point of 40.5°C (105°F) or greater and be compatible with unit components. Solvent exposed to open flame or sparks, or spilled onto any hot surfaces or electrical components, can cause a fire, resulting in personal injury or death.

Personal injuries can occur as a result of using pressurized air.

Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes.

Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

Entanglement

To prevent hazardous fire conditions, all solvents, materials, and filters used with or on the workstation must be handled and disposed of properly. This is very important when working with solvents. Follow all federal, state, and local regulations on disposal of waste products.

WARNING To prevent serious injury or death, always use extreme caution when polishing the crankshaft journals, or whenever a component is rotating in the workstation. Do not wear loose clothing or gloves, and stay clear of the rotating component.

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• The valve controlled solvent hose attaches to an air/solvent mixing nozzle for efficient cleaning or drying procedures.

General Information Section

• The large solvent collection tray and dual drain-back pipes ensure efficient cycling of the solvent back into the sump.

• Five splash shields easily lock into place on the front of the workstation to increase solvent recovery during cleaning procedures.

• A pressure air supply manifold pipe is mounted along the front of the workstation and features three locations for quick disconnect fittings (dealer supplied).

• Dual dial indicator sets are included with the crankshaft workstation. They mount to sliding fixture arms on the front of the workstation for conveniently checking straightness and runout.

• The 454 L (120.0 gal) sump is located behind the workstation main body and features a high-flow pump that ensures consistent solvent supply.

• The main control valve on the solvent pump outlet regulates total solvent flow to the solvent filters and on to the flex pipe manifold.

• A cleanable mesh filter and two canister filters with service gauges ensure a full-flow system that provides clean solvent to the flex pipe manifold.

• Controls on the crankshaft workstation provide forward and reverse rotation with a gradual Start and Stop feature. An adjustable rpm control and Jog button allow precise crankshaft rotation.

• Both the headstock and tailstock chuck jaws feature 304 mm (12 in) diameter capacity and secure clamping using the large T-handle chuck wrench.

• The adjustable tailstock allows various lengths of crankshafts and camshafts to fit between the chuck jaws.

• Two adjustable V-blocks clamp into position to support the crankshaft or camshaft during inspection, cleaning, and for checking straightness.

• Nineteen flex pipes feature individual control valves to precisely direct solvent flow during cleaning.

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Nomenclature

(2) Powered Headstock Chuck. (4) Fixture Arm Tube.

(6) Pressure Air Manifold Pipe. (23) Updated Control Panel Enclosure.

(1) Workstation Main Body.

(3) Adjustable Tailstock Chuck.

(7) Flexible Solvent Nozzles With ON/OFF Valves.

(8) Cleaning Nozzle Solvent Supply Valve.

(9) Solvent/Air Cleaning Nozzle. (10) Splash Guards.

(13) Gear Box with Electric Motor.

(4) Fixture Arm Tube. (5) Fixture Arm. (20) Dial Indicator Group. (21) Aluminum Extension Arm. (22) V-Blocks.

Consumable Parts Consumable Parts Part Number

(14) Solvent Sump Assembly. (15) Solvent Pump Group.

(16) Solvent Flow Control Valve. (17) Mesh Strainer.

(18) Ten Micron Filter. (19) Two Micron Filter.

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Description

Qty.

9U-5870

Ten Micron Filter

1

198-3188

Two Micron Filter

1

5P-8636

V-Block Wear Pad

4

7F-7836

Special Screw (For Wear Pad)

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Specifications

Additional Contact Information For further assistance for ordering or for information on other specialized tooling for your service operation, contact:

Specifications for Crankshaft Workstation Description

Specification

Power Supply

380 Volt, 50 Hertz, 3 Phase

Maximum Distance Between Drive Chuck and Tailstock

330 cm (130.0 in)

Center of Chuck To Base

406 mm (16.0 in)

Chuck Jaw Opening

304 mm (12.0 in)

Variable Rotation Speed

5 to 60 rpm

Solvent Pump

5.5 kW (7.4 hp)

Maximum Capacity of Sump

454 liter (120.0 gal)

John Jordan 8900 N. Pioneer Road Peoria, IL 61615-1522 Telephone: 309-636-1791 Fax: 309-636-1664 Jordan_John_A@cat.com or Allan Teuerle 8900 N. Pioneer Road Peoria, IL 61615-1522 Telephone: 309-636-1677 Fax: 309-636-1664 Teuerle_Allan_R@cat.com

Crankshafts Engine

Crankshaft

3406

0R3780, 0R3972

3408

0R2657, 0R4828

3412

0R9751

3508

0R8502

3512

0R9736

3516

0R9737, 0R9738HD

3524

0R9739 front

3524

0R9740 rear

or Hotline Sue Hughes Dealer Service Tools 501 S.W. Jefferson Ave. Peoria, IL U.S.A. 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

References SEBF8039

Guideline for Reusable Parts Inspection of Crankshafts for Cracks

SEBF8041

Guideline for Reusable Parts and Salvage Operations Specifications for Crankshafts in Caterpillar Engines

SEBF8042

Guideline for Reusable Parts and Salvage Operations Procedure to Grind and Polish Crankshafts

SEBF8043

Guideline for Reusable Parts Visual Inspection of Crankshafts

SEBF8054

Guideline for Reusable Parts and Salvage Operations Procedure to Measure and Straighten Bent Crankshafts

SEBF8097

Guideline for Reusable Parts and Salvage Operations Camshaft Measurement

SEBF8156

Guideline for Reusable Parts and Salvage Operations Procedure to Inspect Crankshafts in 3500 Family of Engines

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2. Locate the main body of workstation (1) in the desired location. Position sump (2) with the pump and motor components directly behind the gear box, as shown.

Assembly Section The workstation is shipped in two sections.

The sump group will be shipped on a separate pallet with other required components.

1. Uncrate and unpack all components.

Report any concealed damage or shortages to Dealer Service Tools.

WARNING NOTE: Make sure the drain pipes are inserted through the corresponding holes in the sump tank.

Some components of the crankshaft workstation weigh enough to cause crushing injury if dropped.

Always wear protective shoes, and use care when handling heavy components during assembly.

NOTE: Locate the workstation to allow access to the sump and filters for maintenance.

3. Level the main body of the workstation using the adjustable feet. Secure the workstation to the floor using appropriate anchors (dealer supplied).

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6. Plug the solvent pump motor connection in the receptacle below the gearbox motor.

4. Align and connect the filter manifold pipe to the pick-up tube outlet using the supplied union fitting. Tighten the fitting securely.

7. Attach the two fixture arms to the outside of the slider assemblies. Remove the four Allen bolts from each threaded lower bracket and install a fixture arm with the four Allen head bolts. Tighten the bolts securely.

WARNING High voltage is present.

Follow all electrical safety procedures to prevent injury or death by electrical hazards.

Consult a qualified electrician to connect the crankshaft workstation for electrical service.

5. Have a qualified electrician make the electrical connections at the lock-out junction switch located inside the control panel of the workstation.

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b. Remove the pipe plug and install a quick disconnect fitting or hose fitting (dealer supplied) in the pressure air inlet location at the left-hand end plate.

Apply teflon tape to the threads of the fitting and tighten securely.

8. If necessary, adjust the lower travel stop on each fixture arm so the upper portion leans away from the workstation. The fixture arms must lean out far enough to permit installation of the splash guards when required.

c. Connect to the shop air supply.

10. Install a quick disconnect fitting or hose fitting (dealer supplied) on the pressure air cleaning/drying nozzle. Apply teflon tape to the threads of the nozzle and tighten securely.

9. Install the fittings in the pressure air manifold pipe. a. Remove three pipe plugs in the pressure air manifold pipe, along the front of the crankshaft workstation.

Install quick disconnect fittings (dealer supplied) in the air outlet locations.

Apply teflon tape to the threads of each fitting and tighten securely.

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11. Fill the sump with 416 L (110 gal) of Special Kustom 221 solvent. This approved solvent is available from Storm Vulcan Mattoni at 1-800-527-2442. Install the covers on the sump.

Operation Section Operating Controls 1. The main power control panel is mounted on the front left-hand corner of the workstation.

2. Main power control switch (1) rotates counterclockwise to the 9 o’ clock position to turn off electrical power to the controls. It also releases the inner lock of the control panel door, allowing it to open.

WARNING Always follow the c h e m i c a l manufacturers instructions for proper handling of solvent. If petroleumbased solvent is used, it must have a flash point of 40.5°C (105°F) or greater and be compatible with unit components. Solvent exposed to open flame or sparks, or spilled onto any hot surfaces or electrical components, can cause a fire, resulting in personal injury or death.

MS SD M SSS DDD M SSS M

(I) ON. (O) OFF.

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4. The headstock chuck controls are on the right-hand side of the panel and include STOP (5), RUN (6), JOG (7) switches, FOR/REV (forward/reverse) Control (8), and Rotation Speed Control (9).

WARNING Pushing the EMERGENCY STOP button shuts off power to the pump and slows the headstock chuck to a stop. To prevent serious injury or death, always use extreme caution when polishing the crankshaft journals, or whenever a component is rotating in the workstation. Do not wear loose clothing or gloves and stay well clear of the rotating component.

3. Large, red EMERGENCY STOP button (2) on the front control panel shuts off power to the pump and gradually slows the headstock chuck to a stop. Red STOP button (3) shuts the solvent pump off.

Green RUN button (4) turns the solvent pump on.

(5) Red Headstock Chuck STOP Button.

(6) Green Headstock Chuck RUN Button.

(7) Black Headstock Chuck JOG Button.

(8) Headstock Chuck FOR/REV (forward/reverse) Control.

(9) Headstock Chuck Rotation Speed Control.

a. Red STOP button (5) shuts OFF power to the headstock chuck motor. Green RUN button (6) turns ON power to the headstock chuck motor.

NOTE: Pushing RUN button (5) causes a gradual ramp up of the headstock chuck to the speed selected at Rotation Speed Control (9). Pushing STOP button (6) causes a gradual ramp down of speed to no movement of the headstock chuck.

(2) EMERGENCY STOP Button.

(3) Solvent Pump STOP Button.

(4) Solvent Pump RUN Button.

NOTE: To reset the EMERGENCY STOP button, turn the knob clockwise and pull out.

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b. JOG button (7) rotates the headstock chuck a slight amount each time it is pushed. Holding the JOG button in causes the headstock chuck to rotate until it is released.

Install Crankshaft in V-Blocks NOTE: In general, the procedures described in this section also apply to camshaft salvage.

Refer to SEBF8097, Guideline for Reusable Parts and Salvage Operations; Camshaft Measurement for additional information.

NOTE: The direction of rotation is dependent on the position of FORWARD/REVERSE switch (8). The amount of rotation depends on the position of Rotation Speed Control (9), the weight of the crankshaft, and how long JOG button (7) is activated.

The V-blocks are used to support and position the crankshaft during cleaning procedures, and straightness/runout checks.

c. FORWARD/REVERSE switch (8) controls the direction of the headstock chuck rotation. In the FORWARD position the headstock chuck rotates towards the operator. In the REVERSE position, it rotates away from the operator.

NOTE: The crankshaft can also be installed in the chuck jaws for cleaning procedures. Refer to the Install Crankshaft In Chuck Jaws section for the proper installation procedure.

1. Clean top of rails (1) and install the two V-blocks. Clamp the V-blocks in place with the lower V-block plates and Allen head bolts. Only tighten the bolts enough to prevent the V-blocks from tipping.

NOTE: Always use STOP button (5) to completely stop the rotation of the headstock chuck before changing the direction of rotation.

NOTE: The V-blocks must sit squarely on the rail surface of the workstation. Make sure this surface is clean and dry before installing the V-blocks.

d. Rotation speed control (9) is calibrated in percent of rotation from 0% (no rotation) to 100% (approximately 60 rpm). Turn the control clockwise to increase rotation speed and counterclockwise to reduce the rotation speed.

(9) Headstock Chuck Rotation Speed Control.

(1) Crankshaft Workstation Rails.

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2. Clean the wear pads of the V-blocks and apply a light film of clean oil.

4. Position the crankshaft with V-blocks under the end main journals. The front of the crankshaft should face the headstock chuck.

3. Use a lifting device and non-marring strap(s) capable of supporting the weight of the crankshaft. Carefully lift the crankshaft and position it above the V-blocks.

5. Lower the crankshaft into the V-blocks.

6. Make sure each V-Block wear pad contacts the area of the main bearing journal between oil hole(s) and journal fillet (A). If necessary, slightly lift the crankshaft and reposition the V-blocks. The crankshaft must be able to rotate smoothly in the V-blocks.

WARNING The crankshaft weighs enough to cause crushing injury if dropped. Always wear protective shoes and use care when handling heavy components.

(A) Acceptable Journal V-Block Placement.

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NOTE: Inaccurate measurements can result if the crankshaft is not properly located on the V-blocks. Make sure each V-block contacts the crankshaft bearing journal in flat areas (A) between the fillet and oil hole(s).

NOTE: The crankshaft can also be installed in the V-blocks for cleaning procedures. Refer to the Install Crankshaft In V-Blocks section for the proper installation procedure.

7. Once the V-blocks are in position, completely tighten the four Allen head bolts using a supplied Allen wrench. Remove the lifting device strap from the crankshaft.

1. Clean the top of the rails and make sure the tailstock housing will slide freely. If necessary, use an Allen wrench to loosen two tailstock clamping bolts.

NOTE: The tailstock housing must sit squarely on the rails of the workstation. Make sure this surface is clean before moving the tailstock housing.

Crankshaft Removed For Photographic Clarity.

Install Crankshaft in Chuck Jaws NOTE: In general, the procedures described in this section also apply to camshaft salvage.

Refer to SEBF8097, Guideline for Reusable Parts and Salvage Operations; Camshaft Measurement for additional information.

2. Make sure the jaw surfaces of both the headstock and tailstock chucks are clean and dry.

The headstock chuck and tailstock chuck are used to support, position, and rotate the crankshaft during cleaning and polishing procedures.

NOTICE The chuck jaws can damage the seal sleeve wear surfaces. If replacement of the wear sleeves is done prior to workstation cleaning/polishing, seal damage and/or oil leaks can occur. Always replace the crankshaft seal wear sleeves after the crankshaft has been processed through the workstation.

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3. Use a supplied T-handle chuck wrench to open both chuck jaws to accept the end journals of the crankshaft.

5. Align the crankshaft with the headstock chuck and position the end journal in the jaws of the chuck.

NOTE: Make sure one of the chuck jaws is oriented at the bottom (180° position) of the headstock chuck with two upper jaws (A) positioned as shown.

4. Use a lifting device capable of supporting the weight of the crankshaft to carefully lift the crankshaft above the bed of the workstation, with the front of the crankshaft toward the headstock.

(A) Upper Headstock Chuck Jaws.

6. Slide the tailstock housing inward to position the rear crankshaft end journal in the chuck jaws. Use an Allen wrench to securely tighten the two tailstock clamping bolts.

WARNING The crankshaft weighs enough to cause crushing injury if dropped. Always wear protective shoes and use care when handling heavy components.

18

7. Position one of the tailstock chuck jaws at the bottom (180° position) of the headstock chuck with two upper jaws (B) positioned as shown.

9. Once the crankshaft is securely clamped in both head stock and tailstock chuck jaws, remove the sling and lifting device.

(B) Tailstock Upper Chuck Jaws.

8. Center the crankshaft end journals in the chuck jaws and use a supplied T-handle chuck wrench to evenly tighten the jaws at all positions around the headstock chuck and the tailstock chuck.

10. Reverse the procedure to remove the crankshaft from workstation.

NOTE: Always support the crankshaft with a sling and lifting device before loosening chuck jaws.

NOTE: Make sure all chuck jaws are securely tightened before running the crankshaft at any speed.

NOTICE Tooling and equipment can be damaged if the crankshaft falls out of the chuck jaws during removal. Always attach the lifting device and sling before loosening chuck jaws

WARNING The crankshaft weighs enough to cause crushing injury if dropped. Always support the crankshaft with sling and lifting device before loosening the chuck jaws. Always wear protective shoes and use care when handling heavy components.

NOTICE Tooling and equipment can be damaged if the crankshaft falls out of the chuck jaws while running. Always securely tighten all chuck jaws before running the crankshaft at any speed.

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2. Make sure all of the solvent flex nozzles are pointed toward the recovery tray of the workstation .

General Wash NOTE: The crankshaft can be cleaned while positioned in the V-blocks or in the chuck jaws.

Refer to the Install Crankshaft in V-Blocks or the Install Crankshaft in Chuck Jaws section for the proper installation procedure.

WARNING To prevent serious injury or death, always use extreme caution when polishing the crankshaft journals, or whenever a component is rotating in the workstation. Do not wear loose clothing or gloves and stay clear of the rotating component.

NOTE: Make sure all solvent flex nozzle valves are in the closed position.

1. Install the splash guards along the front of the workstation. The guard without interlocking tabs is the first guard that should be installed. Install this splash guard closest to the headstock chuck.

Valves Shown in Closed (Off) Position.

3. Make sure the solvent flow control valve on the sump is open.

NOTE: Solvent flow can be regulated by partially closing the valve to reduce pressure.

20

6. If the crankshaft is mounted in the chuck jaws, use the headstock controls to rotate the crankshaft while washing with solvent.

4. Turn the solvent pump on and open the flex nozzle valves, as needed, to direct the flow of filtered solvent to clean the crankshaft.

WARNING To avoid eye injury, always wear protective glasses or face shield when solvent is used for cleaning. Make sure no one can be injured by liquids or flying debris when using the crankshaft workstation.

5. The end valve on the solvent manifold controls solvent flow to the hand-held cleaning nozzle. The cleaning nozzle can be used with pressure air to clean the crankshaft. Connect a pressure air line to the nozzle air fitting.

NOTE: The air nozzle trigger controls pressure air and the manifold valve controls solvent flow.

(5) Red Headstock Chuck STOP Button.

(6) Green Headstock Chuck RUN Button.

(7) Black Headstock Chuck JOG Button.

(8) Headstock Chuck FOR/REV (forward/reverse) Control.

(9) Headstock Chuck Rotation Speed Control.

NOTE: To prevent unwanted movement of the crankshaft, always make sure Rotation Speed Control (9) is turned counterclockwise to 0 before pushing green RUN button (6). a. Select the direction of rotation with FOR/REV (forward/reverse) button (8). b. Push green RUN button (6). c. Turn Rotation Speed Control (9) clockwise to rotate the crankshaft.

WARNING

NOTE: Rotate the crankshaft at a slow speed to prevent splashing the solvent.

Pushing the EMERGENCY STOP button shuts off power to the pump and slows the headstock chuck to a stop. To prevent serious injury or death, always use extreme caution when polishing the crankshaft journals, or whenever a component is rotating in the workstation. Do not wear loose clothing or gloves and stay well clear of the rotating component.

21

Checking Crankshaft Straightness

WARNING

NOTE: Refer to the following manual for additional information on checking straightness.

To prevent serious injury or death, always use extreme caution when polishing the crankshaft journals, or whenever a component is rotating in the workstation. Do not wear loose clothing and stay clear of the rotating component.

SEBF8054

Guideline for Reusable Parts and Salvage Operations Procedure to Measure and Straighten Bent Crankshafts

NOTE: In general, many crankshaft procedures described in this manual also apply to camshaft salvage. Refer to SEBF8097, Guideline for Reusable Parts and Salvage Operations; Camshaft Measurement for additional information.

7. Connect a pressure air hose and air nozzle (dealer supplied) to one of three pressure air fittings on the pressure air manifold pipe. Use pressure air to thoroughly dry the crankshaft.

WARNING

Preventing axial movement of the crankshaft during the thrust bearing runout measurement requires the use of a dealer supplied 19.7 to 25.4 mm (.62 to 1.00 in) diameter hardened steel ball and a 22.9 x 2 cm (9.00 x .75 in) ground, hardened steel plate.

Personal injuries can occur as a result of using pressurized air.

Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes.

Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

22

1. Clamp the ground, hardened steel plate in the headstock chuck of the workstation.

NOTE: A small amount of clean grease on the steel ball will help hold it in the machined center on the front of the crankshaft and lubricate the contact point against the hardened steel plate.

4. Push the crankshaft forward so the steel ball contacts the hardened steel plate.

5. Make sure each V-block wear pad contacts the area of the main bearing journal between the oil hole(s) and journal fillet (A).

If necessary, slightly lift the crankshaft and reposition the V-blocks. The crankshaft must be able to rotate smoothly in the V-blocks.

2 Lift the crankshaft into position and support it with V-blocks under the end main bearing journals (refer to the Installing Crankshaft in V-Blocks section). Make sure the front of the crankshaft faces the hardened steel plate.

3. Place the steel ball in the machined center on the front of the crankshaft.

(A) Acceptable Journal V-Block Placement.

NOTE: Inaccurate measurements can result if the crankshaft is not properly located on the V-blocks. Make sure each V-block contacts the crankshaft bearing journal in flat areas (A) between the fillet and oil hole(s).

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8. Refer to SEBF8054, Procedure to Measure and Straighten Bent Crankshafts for guidelines on measuring crankshaft straightness.

6. Once the V-blocks are in position, completely tighten the four Allen head bolts using a supplied Allen wrench. Remove the lifting device strap from the crankshaft.

Crankshaft Removed For Photographic Clarity.

Polishing Crankshaft Journals 7. Install the aluminum extension bracket(s) and dial indicator(s) on the sliding fixture arms, as needed.

NOTE: Refer to the following manual for additional information on polishing crankshaft journals.

SEBF8042

Guideline for Reusable Parts and Salvage Operations Procedure to Grind and Polish Crankshafts

NOTE: In general, many crankshaft procedures described in this manual also apply to camshaft salvage. Refer to SEBF8097, Guideline for Reusable Parts and Salvage Operations; Camshaft Measurement for additional information.

NOTICE Dial indicators are precision instruments and are easily damaged. Only install the aluminum bracket and dial indicator group on the vertical arms when measuring runout. Remove and store the dial indicator groups in a clean, dry location when not in use.

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1. If not already installed, place the crankshaft in the chuck jaws. Refer to the Installing Crankshaft in Chuck Jaws section for the complete procedure.

2. Use headstock chuck controls to rotate the crankshaft in the desired direction and speed.

NOTICE The chuck jaws can damage the seal sleeve wear surfaces. If replacement of the wear sleeves is done prior to workstation cleaning/polishing, seal damage and/or oil leaks can occur. Always replace the crankshaft seal wear sleeves after the crankshaft has been processed through the workstation.

(5) Red Headstock Chuck STOP Button.

(6) Green Headstock Chuck RUN Button.

(7) Black Headstock Chuck JOG Button.

(8) Headstock Chuck FOR/REV (forward/reverse) Control.

(9) Headstock Chuck Rotation Speed Control.

NOTE: Polishing crankshaft journals requires the use of a hand-held electric or air powered high speed polisher (dealer supplied).

NOTE: To prevent unwanted movement of the crankshaft, always make sure Rotation Speed Control (9) is turned completely counterclockwise to 0 before pushing green RUN button (6).

WARNING Pushing the EMERGENCY STOP button shuts off power to the pump and slows the headstock chuck to a stop. To prevent serious injury or death, always use extreme caution when polishing the crankshaft journals, or whenever a component is rotating in the workstation. Do not wear loose clothing or gloves and stay well clear of the rotating component.

a. Select the direction of rotation with FOR/REV (forward/reverse) button (8). b. Push green RUN button (6). c. Turn Rotation Speed Control (9) clockwise to rotate the crankshaft at the desired speed.

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Maintenance Section

WARNING

Filter Service

To prevent serious injury or death, always use extreme caution when polishing the crankshaft journals, or whenever a component is rotating in the workstation. Do not wear loose clothing and stay clear of the rotating component.

Check and clean the mesh filter on a regular basis. Monitor the two filter gauges, and replace the filter elements when a gauge reads in the red “Service Filter” range.

WARNING To avoid exposure to s t r o n g chemicals, always wear protective glasses or face shield and protective clothing when servicing filters or replacing solvent.

3. Refer to SEBF8042, Procedure to Grind and Polish Crankshafts, for guidelines and procedures to polish crankshaft bearing journals.

Clean up all leaked or spilled fluids immediately.

Oil, fuel, or solvents leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area, and clean up all spilled fluids immediately.

Always consult the Material Safety Data Sheet for chemical hazards and first aid instructions. These sheets should be available from the manufacturer/supplier of the solvent.

MS SD M SSS DDD M SSS M

NOTICE Tooling and equipment can be damaged if the crankshaft falls out of the chuck jaws while running. Always securely tighten all chuck jaws before running the crankshaft at any speed.

To prevent hazardous fire conditions, all solvents, materials, and filters used with or on the workstation must be handled and disposed of properly. This is very important when working with solvents. Follow all federal, state, and local regulations on disposal of waste products.

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4. Loosen the large hex head sleeve-nut in the top of the mesh filter housing.

Mesh Filter Use the following procedure to clean the mesh filter.

WARNING To prevent hazardous fire conditions, all solvents, materials, and filters used with or on the workstation must be handled and disposed of properly. This is very important when working with solvents. Follow all federal, state, and local regulations on disposal of waste products.

5. Remove the sleeve-nut, canister, rubber gasket, and mesh filter.

1. Turn power to the workstation OFF.

6. Clean the components thoroughly and reinstall on the canister housing.

(I) ON. (O) OFF.

2. Place a suitable container under the mesh filter canister.

7. Tighten the square drain plug and hex sleeve-nut securely.

3. Remove the square drain plug in the bottom of the mesh filter canister and drain the dirty fluid into the container.

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Filter Elements

3. Loosen and remove the filter.

Use the following procedure to replace the ten micron and two micron filters.

4. Drain the filter and discard. Follow all federal, state, and local guidelines for proper disposal of filter.

WARNING

5. Put a thin film of clean oil on the new filter gasket and install it in the groove of the filter housing. Install the filter. Consult the information printed on the filter for proper tightening procedures.

To prevent hazardous fire conditions, all solvents, materials, and filters used with or on the workstation must be handled and disposed of properly. This is very important when working with solvents. Follow all federal, state, and local regulations on disposal of waste products.

NOTE: Always remove the old filter gasket from the filter housing and replace with the gasket supplied with the new filter.

6. Replace the 198-3188 Two Micron Filter element using the same steps.

1. Turn power to the workstation OFF.

198-3188 Two Micron Filter.

(I) ON. (O) OFF.

Solvent Replacement 2. Place a suitable container under the 9U-5870 Ten Micron Filter.

Solvent life depends on frequency of use and the type of cleaning. Replace the solvent on a regular basis or when the solvent is no longer effectively cleaning the parts.

NOTE: Dirty solvent can result in more frequent servicing of filters.

9U-5870 Ten Micron Filter.

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WARNING

WARNING

To avoid exposure to s t r o n g chemicals, always wear protective glasses or face shield and protective clothing when servicing filters or replacing solvent.

Always follow the c h e m i c a l manufacturers instructions for proper handling of solvent. If petroleumbased solvent is used, it must have a flash point of 40.5°C (105°F) or greater and be compatible with unit components. Solvent exposed to open flame or sparks, or spilled onto any hot surfaces or electrical components, can cause a fire, resulting in personal injury or death.

MS SD M SSS DDD M SSS M

Clean up all leaked or spilled fluids immediately.

Oil, fuel, or solvents leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

1. Turn power to the workstation OFF.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area, and clean up all spilled fluids immediately.

Always consult the Material Safety Data Sheet for chemical hazards and first aid instructions. These sheets should be available from the manufacturer/supplier of the solvent.

MS SD M SSS DDD M SSS M

To prevent hazardous fire conditions, all solvents, materials, and filters used with or on the workstation must be handled and disposed of properly. This is very important when working with solvents. Follow all federal, state, and local regulations on disposal of waste products.

(I) ON. (O) OFF.

2. Remove the solvent sump covers.

Use the following procedure to replace the solvent and clean the solvent sump.

NOTE: It is recommended that the mesh filter be cleaned and the ten micron and two micron filters be changed whenever solvent is replaced.

29

3. Use a portable pump to transfer the dirty solvent into suitable container(s) for proper disposal. Remove any sediment from the bottom of the solvent sump.

Workstation Collection Tray 1. Periodically remove debris and sediment from the collection tray between the workstation rails.

NOTE: Make sure the area around the workstation pump pick-up is clear of all debris and sediment.

2. Make sure the area around the solvent drain back tubes remains clear.

4. Refill the sump with 416 L (110 gal) of Special Kustom 221 solvent. This approved solvent is available from Storm Vulcan Mattoni at 1-800-527-2442. Install the covers on the sump.

5. Replace the solvent sump covers.

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3. Replace the V-block wear pads and special screws, as required, due to wear or damage.

Other Maintenance 1. Check and tighten the six Allen head bolts attaching the chuck jaws to each chuck assembly.

NOTE: Refer to Consumable Parts list for the correct part numbers.

NOTE: For torque specifications, contact Storm Vulcam Mattoni at 1-800-527-2442.

2. The slide tube that the dial indicator fixture arms mount on must be kept clean and rust free. Apply a very light film of clean oil, as required, to allow the dial indicator mounts to easily move on the slide tube.

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For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL U.S.A. 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

©2006 Caterpillar All Rights Reserved

NEHS0956 Printed in U.S.A.