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Guideline For Reusable Parts And Salvage Operations Visual Inspection of Camshaft

Visual Inspection of Camshaft

Introduction

This Guideline enables dealers and their customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current and relevant information known to Caterpillar Inc. Since the Company makes ongoing changes and improvements to its products, this Guideline must be used with the latest technical

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Media Number -SEBF8146-04 Publication Date -26/10/2004 Date Updated -27/10/2004

SEBF81460001

GUIDELINE FOR REUSABLE PARTS AND SALVAGE OPERATIONS

CAT®

Visual Inspection of Camshaft SEBF8146-04

SMCS Code: 1210September 2004

Summary of Revisions Page Description All Revised Format.

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information available from Caterpillar to ensure such changes and improvements are incorporated where applicable.

For questions or additional information concerning this Guideline, contact Caterpillar Service Support Division, Dealer Support (309) 675-5434.

Summary

This Guideline applies to camshafts for all engines regardless of bore size. It will give visual guidelines to show the difference between a reusable camshaft and one that is not reusable. This Guideline and SEBF8097, "Camshaft Measurement", must be used to determine if a camshaft is either reusable, requires repair, or needs to be replaced with a new camshaft.

Never use a camshaft that this Guideline shows cannot be used again.

If the camshaft meets the requirement set forth in this Guideline and SEBF8097 it can be expected to give normal performance until the next overhaul, when used again in the same application.

References

Equipment for Crack Inspection and Polishing

References Form No. Title Guideline for Reusable Parts

SEBF8042 Procedure for Polish Crankshafts SEBF8067 Slipper Follower and Camshaft

Roller Followers SEBF8097 Camshaft Measurement

Service Magazine May 16, 1977 Correct Installation of Valve Lifters

on the Camshaft is Very Important to Prevent Failures

Page 2 of 30Media Search - SEBF8146 - Visual Inspection of Camshaft


Illustration 1

Inspection for cracks with a Magnaflux inspection machine.

Illustration 2

Equipment needed to polish camshafts.



The procedure, materials, and equipment required to polish camshafts are identical to polishing crankshafts. Refer to SEBF8042, "Procedure to Polish Crankshafts" for polishing instructions.

General Information

Before Visual Inspection

Immediately after the camshaft has been removed from the engine, look for any clear signs of heavy damage that cannot be corrected by reconditioning.

Clean the camshaft with a high-pressure wash, steam, solvent, vapor degreaser, or caustic bath and rinse.

Slipper Follower Camshaft

1. For good service life, install each slipper follower in its original location, so that it runs against the same camshaft lobe.

2. A new slipper follower can be installed on a used camshaft, if the camshaft meets reusability guidelines.

3. If a new camshaft is installed, use new or reconditioned followers.

Nomenclature

NOTICE

If the camshaft will not be inspected immediately (less than one hour after it is cleaned), put a layer of engine oil on the journals and lobes to prevent corrosion.



Illustration 3

Camshaft nomenclature.

Nose.

(2) Ramp.

(3) Bearing journal.

(4) Tapered lobe.

(5) Flat lobe.

(B) Base circle.

Illustration 4

Lobe measurement to calculate lift dimension.

To calculate the lift dimension, measure the total lobe height at location (A), and measure the base circle diameter at location (B). The formula is (A) minus (B) equals lift (C).

Location (A) 71.33 mm (2.80 in) Location (B) 57.60 mm (2.26 in) Location (C) 13.73 mm (0.54 in)



Therefore, the lift dimension is 13.73 mm (0.54 in).

Corrosive Damage

Illustration 5

Corrosive damage.

(A) Stain.

Use again

(B) Surface rust.

Use again -

After polishing if rust is only on the base circle and covers less than 10% of the total base circle. Polishing must remove all surface rust.

(C) Surface pitted.

Do not use again -

If pitting is caused by rust.



Minor Debris Damage (Indentations)

Illustration 6

Minor debris damage.

Use again -

After polishing.

Refer to Guideline For Reusable Parts, SEBF8042, "Procedure to Polish Crankshafts", for polishing instructions.

Illustration 7



Typical.

Use again -

If the mating lifter surfaces show a mirror-like polish. Must be matched with lobe, lifter, and engine.

Illustration 8

Normal slipper wear pattern.

Use again -

After measurement and polishing.



Illustration 9

Typical.

Use again

Illustration 10

Typical.

Use again -



Note: If a slipper follower camshaft shows wear, then it is only reusable when used in the original block with original lifters, matched to the appropriate lobe. The lifter must have mirror-like surface before the camshaft and lifter can be reused.

Illustration 11

Typical.

Use again

Illustration 12



Typical.

Use again

Illustration 13

Typical.

Use again -

With the original lifters.



Illustration 14

Use again -

After measurement and polishing.

Illustration 15

Use again -

With the original lifters.

Note: If the slipper follower camshaft shows wear, then it is only reusable when used in the original block with original lifters, matched to the appropriate lobe. The lifter must have a mirror-like surface before the lifter and camshaft can be reused.



Illustration 16

Surface pitting.

(A) Surface pitting.

(B) Surface pitting on nose or ramp.

Do not use again

Pitting

Illustration 17

Surface pitting.



Do not use again

Illustration 18

Chip of metal missing from nose.

Do not use again

Welded Lobes

Caterpillar Inc. does not recommend using any camshafts with welded lobes. Caterpillar currently does not endorse the welding of cast camshafts.



Illustration 19

Do not use again

Illustration 20

Do not use again



Illustration 21

Do not use again

Roller Follower Camshaft

4. Always install used roller followers in their original locations and original direction.

5. A new roller follower can be installed on a used camshaft if the camshaft meets reusability guidelines.

6. New roller followers should be installed on new camshaft segments.

7. If replacement of a camshaft is the result of damage to one or more of its lobes, do not reuse the followers that operated against the damaged lobes.

Nomenclature



Illustration 22

Camshaft nomenclature.

(1) Nose (2) Ramp (3) Bearing journal (5) Flat lobe (B) Base circle

Illustration 23

Lobe measurement to calculate the lift dimension.

To calculate the lift dimension, measure the total lobe height at location (A), and measure the base circle diameter at location (B). The formula is (A) minus (B) equals lift (C).

Corrosive Damage



Illustration 24

Corrosive damage.

(A) Stain.

Use again

(B) Surface rust.

Use again -

After polishing if rust is on the base circle and covers less than 10% of the total base circle. Polishing must remove all surface rust.

(C) Surface pitting.

Do not use again -

if pitting is caused by rust.

Minor Debris Damage (Indentations)



Illustration 25

Use again -

after polishing

Illustration 26

Typical.

Use again



Illustration 27

Typical roller wear pattern.

Use again -

After measurement.

Illustration 28

Chip (A) from edge out of wear pattern. Check for case crushing with Magnaflux.

Use again -



After measurement and polishing. Remove any burrs or raised material.

(A) Chipped from handling.

Use again -

If chip is outside the roller contact zone when assembled (contact zone can change when other parts are changed).

(B) Deep debris tracks.

Do not use again

(C) Shallow debris tracks.

Use again

Illustration 29

Rust (corrosive pitting), possible case crushing.

Use again

After Magnaflux inspection and polishing to determine if the camshaft is reusable.



Fatigue Pitting

Illustration 30

Initial fatigue pitting from edge loading.

Do not use again

Illustration 31




Do not use again

Illustration 32


Do not use again

Illustration 33



Fatigue pitting started by edge loading.

Do not use again

Illustration 34

Do not use again

Case Crushing

Illustration 35



Case Crushing in roller wear pattern.

Do not use again

Illustration 36

Do not use again

Illustration 37.

Case crushing.



Do not use again

Illustration 38

Case crushing.

Do not use again

Illustration 39

Case crushing.



Do not use again

Storage Procedures

Proper protection of the camshaft from corrosion is very important. Corrosion can start within minutes after the camshaft has been cleaned. It must be inspected and protected as soon as possible. If the storage period is expected to be less than three months, a layer of engine oil must be put on the complete camshaft. If a longer period of storage is desired, apply rust inhibitor as recommended in the chart. Complete instructions on the application and removal of these materials are available from the manufacturers.

Suppliers of Magnetic Particle Testing Equipment

Hanco International Division of Hannon Electric Co. 1605 Waynesburg Dr. Canton, Ohio 44707 USA Telephone: (330) 456-4728

Chart A. Recommended Rust InhibitorRust Inhibitor Manufacturer

3 Months to 1 YearSAFECOTE A Daubert Chemical Company

S. Central Ave. Chicago, IL 60638 USA Telephone: (708) 496-7350

1 Year to 2 Years PDRD PENETRANT

RUST PREVENTATIVE 707

Sprayon Products, Inc. 26300 Fargo Ave. Bedford Heights, OH 44146 USA Telephone: (216) 292-7400

Over 2 Years NOX-RUST 110 Daubert Chemical Company

S. Central Ave. Chicago, IL 60638 USA Telephone: (708) 496-7350



Kwik-Way Manufacturing Company 500 57th Street Marion, Iowa 52302, USA Telephone: (319) 377-9421



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