3145, 3150 & 3160 INDUSTRIAL ENGINES Caterpillar

Crankshaft

9L8123 Crankshaft, part of 9L8127 Crankshaft Assembly.9L8122 Crankshaft, part of 9L8128 Crankshaft Assembly.9L8400 Crankshaft, part of 9L8142 Crankshaft Assembly.

The bearing journal surface hardness is extremely thin, .0003 to .0005 in. (0.008 to 0.013 mm). It is important to maintain rigid size control on the bearing journals. Connecting rod journal diameter is 2.7500 ± .0004 in. (69.850 ± 0.010 mm). Connecting rod journal minimum permissible diameter is 2.7486 (69.814 mm). Main bearing journal diameter is 3.5000 ± .0005 in. (88.900 ± 0.013 mm). Main bearing journal minimum permissible diameter is 3.4985 (88.862 mm). Measure the journals around the diameter to find the maximum wear point. Replace the crankshaft if excessive wear is noted on any journal. To check crankshaft for straightness, support at each end in V-blocks, measure the total indicator reading at the center main journal. The maximum permissible runout is .006 in. (0.15 mm) for 4.1 stroke, .007 in. (0.18 mm) for 4.5 stroke, and .008 in. (0.20 mm) for 5.0 stroke crankshafts.

With the crankshaft installed in the cylinder block, check crankshaft end play. End play with new bearings should be .006 ± .003 in. (0.15 ± 0.08 mm). Maximum allowable end play is .014 in. (0.36 mm).

Crankshaft

9L9230 Crankshaft, part of 9L7604 Crankshaft Assembly.9L9231 Crankshaft, part of 9L7603 Crankshaft Assembly.9L9232 Crankshaft, part of 9L7605 Crankshaft Assembly.9N8013 Crankshaft, part of 9L6266 Crankshaft Assembly.4N8453 Crankshaft, part of 4N9054 Crankshaft Assembly.4N8454 Crankshaft, part of 4N9055 Crankshaft Assembly.9N300 Crankshaft, part of 9N305 Crankshaft Assembly.9N303 Crankshaft, part of 9N304 Crankshaft Assembly.

Reconditioning of these crankshafts can be done by grinding the "journals" (bearing surface on the crankshaft for the connecting rod bearings and main bearings) .010 in. (0.25 mm) or .020 in. (0.51 mm) "undersize" (smaller than the original size).

The diameter of the "journals" for the connecting rod bearings is 2.7500 ± .0004 in. (69.850 ± 0.010 mm). The diameter of the "journals" for the main bearings is 3.5000 ± .0005 in. (88.900 ± 0.013 mm). The minimum permissible diameter of the "journals" for the connecting rods is 2.7486 in. (69.814 mm). The minimum permissible diameter of the "journals" for the main bearings is 3.4985 in. (88.862 mm). Measure each "journal" in several places around the diameter to find the maximum wear point. If the diameter of any "journal" is smaller than the minimum permissible diameter, grind all of the "journals." Before grinding a crankshaft, check the crankshaft for being straight. To check a crankshaft for being straight, support each end main bearing "journal" in V-blocks. Using a dial indicator, position the indicator at the zero reading then measure the total indicator reading at the other three main bearing "journals." The maximum total indicator reading is .006 in. (0.15 mm) at the center main bearing "journal" and .003 in. (0.08 mm) at the other two main bearing "journals." If total indicator reading is more than that given but less than .030 in. (0.76 mm) the crankshaft can be "straightened" (made straight). Before "straightening" (making straight) a crankshaft, get temperature of the crankshaft to 400° F (204° C). For the specifications for grinding a crankshaft, see the topic CRANKSHAFT GRINDING SPECIFICATIONS.

With the crankshaft installed in the cylinder block, check the end play for the crankshaft. End play for the crankshaft is .006 ± .003 in. (0.15 ± 0.08 mm). Maximum permissible end play for the crankshaft is .014 in. (0.36 mm).

NOTE: If end play for the crankshaft is more than the maximum permissible end play, check the crankshaft thrust bearing.

Crankshaft Grinding Specifications

DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.

The dimensions and finish for grinding crankshafts are as follows:

Diameter (A) for connecting rod bearing journals is;

.010 in. (0.25 mm) Undersize ... 2.7400 ± .0004 in.(69.596 ± 0.010 mm)

.020 in. (0.51 mm) Undersize ... 2.7300 ± .0004 in.(69.342 ± 0.010 mm)

Surface finish must be 10 micro inches (0.25 micrometers) or less.

Radius (B) must be .100 ± .010 in. (2.54 ± 0.25 mm).

Surface finish must be 63 micro inches (1.6 micrometers) or less.

The radius must blend smoothly with the newly machined journals.

Width (C) is 2.314 +.006 -.003 in. (58.77 +0.15 -0.08 mm).

Diameter (D) for main bearing journals is;

.010 in. (0.25 mm) Undersize ... 3.4895 ± .0005 in.(88.633 ± 0.013 mm)

.020 in. (0.51 mm) Undersize ... 3.4795 ± .0005 in.(88.378 ± 0.013 mm)

Surface finish must be 10 micro inches (0.25 micrometers) or less.

Radius (E) must be .095 ± .010 in. (2.41 ± 0.25 mm).

Surface finish must be 63 micro inches (1.6 micrometers) or less.

The radius must blend smoothly with the newly machined journals.

Width (F) is 1.258 +.004 -.002 in. (31.95 +0.10 -0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 30 micro inches (0.75 micrometers) or less.

Width (F) is 1.268 +.020 -.010 in. (32.21 +0.51 -0.25 mm) for number 2, 3, and 5 main bearing journals.

There is no width (F) for number 1 main bearing journal.

When grinding a crankshaft, no material can be removed from the crankshaft webs or counter-weights.

Crankshaft Gear Removal

Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B7561 Step Plate, and 8H684 Ratchet Box Wrench.

PULLING CRANKSHAFT GEAR

The 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 9S5800 Pump Group.

USING HYDRAULIC PULLER

Crankshaft Gear Installation

1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.

2. Heat gear to 500° F. (260° C) maximum.

3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.

Crankshaft Wear Sleeve Removal

REMOVING WEAR SLEEVE

Use the 8S7164 Wear Sleeve Puller Group to remove the wear sleeve.

Crankshaft Wear Sleeve Installation

WEAR SLEEVE INSTALLATION TOOLS
1. 5P290 Pilot. 2. 5P286 Ring. 3. 9S8858 Nut. 4. 1P5515 Bolts. 5. 9S8864 Pusher Plate.

To install the wear sleeve, use the following procedure:

1. Install 5P290 Pilot (1) on the end of the crankshaft. Install 1P5515 Bolts (4) and tighten just enough to hold pilot (1) yet allow some side movement. Put the wear sleeve on pilot (1) with the chamfer toward the rear of the engine. Push the wear sleeve on the crankshaft to put pilot (1) in the center, then tighten bolts (4).

2. Put 5P286 Ring (2) on 9S8864 Pusher Plate (5) and place this assembly on the stud of pilot (1). Install 9S8858 Nut (3) and tighten nut to push wear sleeve on to the crankshaft.

Crankshaft Rear Oil Seal Removal

Use the 1P3075 Puller Group to remove the crankshaft rear seal.

REMOVING REAR OIL SEAL (Typical Example)

Crankshaft Rear Oil Seal Installation

REAR OIL SEAL INSTALLATION TOOLS
1. 5P290 Pilot. 2. 1P5515 Bolts. 3. 5P285 Ring. 4. 9S8858 Nut. 5. 5P288 Ring. 6. 9S8864 Pusher Plate.

To install the crankshaft rear oil seal, use the following procedure:

1. Install 5P290 Pilot (1) on the crankshaft with 1P5515 Bolts (2). Install 5P288 Ring (5) on pilot (1).

2. Put 7F2770 Cement on the outer diameter of the seal metal shell. Put engine oil on the lip of the seal. Install the seal on the pilot with the lip of the seal toward the front of the engine.

3. Install 9S8864 Pusher Plate (6) and 5P285 Ring (3) over pilot (1). Install 9S8858 Nut (4). Tighten nut (4) until ring (5) makes contact with the flywheel housing.

NOTE: To prevent possible oil leakage, install a new wear sleeve each time the rear oil seal is replaced.

Crankshaft Front Oil Seal (1100, 3100, and 3208 Engines 79V1-79V1407)

The crankshaft front oil seal can be removed with the timing gear cover on or off the engine. To install the seal to the proper depth, the timing gear cover must be on the engine.

A new timing gear cover permits the crankshaft front oil seal to be installed to two depths.

Use the 9S6030 Installation Group which includes the 8S2276 Installer and 9S6012 Spacer to install the seal. To install seal to the original depth, use only the 8S2276 Installer. To obtain an additional wear track, use the 9S6012 Spacer with the 8S2276 Installer.

The new timing gear cover is installed on engines effective with the following Serial Numbers. 1140 (36B996-up), 1145 (97B2077-up), 1150 (96B1748-up), 1160 (95B3833-up), 3145 (96M437-up), 3150 (97M375-up), 3160 (98M450-up), 3145 Electric Set (65P215-up), 3150 Electric Set (66P220-up), 3160 Electric Set (67P180-up), 3160 Marine Engine (68P1-up), 613 Tractor Engine (71M295-up), 3208 (79V1-79V1407).

Continue to service the earlier cover with the 8S2276 Installer only.

Crankshaft Front Oil Seal Removal

Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.

REMOVING FRONT OIL SEAL (Typical Example)

Crankshaft Front Oil Seal Installation (1100, 3100, and 3208 Engines 79V1-79V1407)

1. Place seal over the short end of the installer. Coat the outer metal shell of the seal with 7F2770 Cement.

NOTE: When seal is installed, the spring-loaded lip must face the inside of the engine.

2. Slide the seal installing tool, with seal, onto the end of crankshaft in place of front pulley.

3. Install the crankshaft pulley retaining bolt and washer. Tighten the bolt. This will press the seal into place. The tool will butt against the crankshaft gear when seal is in place.

4. Lubricate the lip of the seal with engine oil (SAE 30) before installing the pulley.

INSTALLING FRONT OIL SEAL

Crankshaft Front Oil Seal Installation (All 3208 Engines Except 79V1-79V1407)

1. Put the seal over the short end of 5P4194 Installer Assembly (A). Put 7F2770 Cement on the outer diameter of the seal metal shell. The lip of the seal must be toward the inside of the engine.

2. Put the seal and installer assembly (A) in position on the end of the crankshaft. Install bolt (1) and washer (2) that hold the crankshaft pulley in place. Tighten bolt (1) until the installer assembly (A) makes contact with the crankshaft gear.

NOTE: If a new wear surface for the front seal is needed, put the 5P4230 Spacer between the seal and flange of the installer assembly.

INSTALLING FRONT OIL SEAL
1. Bolt. 2. Washer. A. 5P4194 Installer Assembly.

3. Put engine oil on the lip of the seal before installing the pulley.

Crankshaft Pulley Removal

1. Remove pulley retaining bolt and washer.

2. Remove the pulley using a 5F7465 Puller Assembly, 8B7560 Step Plate, two 5M2894 Washers, and two S1571 Bolts.

PULLEY REMOVAL (Typical Example)

Crankshaft Pulley Installation (1100, 3100, and 3208 Engines 79V1-79V1407)

1. Lubricate lip of crankshaft front oil seal and the sealing surface of crankshaft pulley with engine oil (SAE 30).

2. When installing pulley, use the 1F1265 Bolt (1), 6B6682 Hardened Nut (2), 8S8287 Thrust Bearing Assembly (3), 9L8339 Washer (4), and four 5F7353 Washers, (located behind 9L8339 Washer).

3. To install pulley, start pulley on crankshaft. Install nut (2), thrust bearing assembly (3), 9L8339 Washer (4), and the four 5F7353 Washers on bolt (1). Turn bolt (1) into crankshaft until it bottoms out. Hold bolt (1) and turn nut (2) to press pulley onto crankshaft. When installed, the pulley hub will contact the crankshaft gear.

4. Remove the tool setup. Install the pulley retaining bolt and washer. Tighten the pulley retaining bolt to 265 ± 35 lb. ft. (360 ± 45 N·m).

INSTALLING PULLEY
1. 1F1265 Bolt. 2. 6B6682 Hardened Nut. 3. 8S8287 Thrust Bearing Assembly. 4. 9L8339 Washer (four 5F7353 washers located behind 9L8339 washer).

Crankshaft Pulley Installation (All 3208 Engines Except 79V1-79V1407)

1. Lubricate lip of crankshaft front oil seal and the sealing surface of crankshaft pulley with engine oil (SAE 30).

2. To install pulley, start pulley on crankshaft. Put screw (4) from the 8B7548 Push Puller into the crankshaft until it bottoms out. Put crossbar (1) from the 8B7548 Push Puller onto screw (4). Install washer (2) and nut (3) on screw (4). Hold screw (4) and turn nut (3) to press pulley onto crankshaft. When installed, the pulley hub will contact the crankshaft gear.

INSTALLING PULLEY
1. Crossbar. 2. Washer. 3. Nut. 4. Screw.

3. Remove the tool setup. Install the pulley retaining bolt and washer. Tighten the pulley retaining bolt to 460 ± 60 lb. ft. (624 ± 80 N·m).