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| CRANKSHAFT REPAIR AND REMANUFACTURING |
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STEP 1) CRANKSHAFT DISASSEMBLY
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Crankshafts are removed from the engine blocks so a visual
inspection of the crank casting can be done. Crankshafts
with bad keyways, journals spun beyond machining specs
or worn thrusts surfaces will be discarded. Adhering to
strict quality standards, Promar will never use a welded
shaft. Once qualified in preliminary inspection, the crank
is then sent for initial cleaning.
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Dirty Crankshaft |
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STEP 2) CRANKSHAFT HIGH-PRESSURE WASH
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The first stop for a qualified crankshaft during our crankshaft repair process is our AXE SW20
OS spray cleaning system. With twice the spraying power
and dramatically increased number of multi-integrated
spray nozzles, the state of the art system assures Promar
that all oil, dirt and foreign material is removed from
even the smallest of oiling holes. The cleanliness of
this crank is essential to insure an accurate magnetic
particle crack detection test.
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Crankshaft After Washing Process |
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AXE SE20 OS Spray Cleaning System |
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STEP 3) CRANKSHAFT MAGNETIC PARTICLE INSPECTION
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Magnetic particle inspection is the most definitive methods
of detecting cracks and imperfections in any ferrous engine
parts. This procedure assures the highest quality cores for crankshaft remanufacturing.
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DCM-2400 Magnetic Particle Inspection |
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STEP 4) CRANKSHAFT GRINDING
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Continuing our efforts to produce the best and most reliable
crankshaft repair product in the industry, we utilize the Berco RTM 225A
precision crankshaft grinder. Coupled with our expert
craftsmen, this state of the art unit incorporates rigid
construction and precise controls; affording Promar customers
the most accurately ground crankshafts possible. Precise
controls afford precision grinding, which is followed
up by brush cleaning and chamfering of all oil passages.
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Berco RTM-225A Precision Crankshaft Grinder |
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Crankshaft Grinding Process |
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STEP 5) CRANKSHAFT HIGH PRESSURE WASH
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Following these precise machining procedures, our cranks
undergo a second high pressure wash cycle to guarantee
the removal of any debris that may have adhered or become
dislodged during the grinding process. Absolute cleanliness
is necessary for the next step of crankshaft remanufacturing, which is micro-polishing
and or balancing if needed.
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AXE SW20 OS Spray Cleaning System
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Crankshaft After Washing Process
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STEP 6) CRANKSHAFT BALANCING
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Promar's digitally controlled balancer is extremely
accurate, producing precise balanced crankshafts during repair, it has
the ability to measure unbalance from .01 to 1,000 grams
on work pieces weighing up to 500 lbs. (226kg). This process
using the Sunnen DCB 2000 is optional for this application.
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Sunnen DCB-2000 |
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Crankshaft Balancing Process |
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STEP 7) CRANKSHAFT MICROPOLISHING
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Promar uses a crankshaft micro polisher with a rigid
polishing system during remanufacturing. The QPAC Q190-38-3 has a solid abrasive
tape that wraps around the journal and is backed up
with a shoe. This shoe applies equal pressure all the
way around the journal while it is being polished.
Traditional polishing techniques use a manually operated
belt sander that can alter the geometry of the journal,
slightly creating some taper or out-of-roundness. If
the surface finish on the crankshaft journal is not
right or the geometry is slightly off, the bearings
will suffer the consequences when the crankshaft is
put into service. While polishing in one direction and
then automatically polishing in the opposite direction,
the QPAC system leaves a better finish and eliminates
microscopic peaks that can cause premature bearing failure.
The finishing process always ends in the same direction
as the engine rotation.
For thrust surfaces, a separate polishing arm is used.
Polishing the thrust surface on the crank is important
to minimize the risk of thrust failure on vehicles that
have electronic torque converters.
With many of today's engines requiring extremely
smooth journal finishes (as low as 6 Ra or less) because
of tighter bearing clearances and the use of thinner
viscosity 5W-30 motor oils, there is little margin for
error. In one pass the QPAC takes the finish down to
6 Ra or less and provides a superior finish to any polishing
systems out there today.
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QPAC Crankshaft Micro-Polisher |
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Crankshaft Polishing Process |
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Crankshaft Ra Check |
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STEP 8) CRANKSHAFT FINAL WASH
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Our spray cleaner system carries twice the horsepower
and twice the amount of nozzles than most spray cabinets.
This machine assures Promar that any dirt, metal or oils
from crankshaft repair and remanufacturing are removed before final assembly.
This is the third and final wash performed after the micro
polishing.
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Crankshaft Rinsing Process |
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Completed & Wrapped Crankshaft |
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