Crankshafts and Crankshafts Parts

Product Details:

Locomotive engines are still in operation in a few countries. We were approached by a client based in Malaysia regarding a problem faced by them in the crankshaft of Locomotive YDM4 ALCO 251. This engine is of an old design and is compact. After studying the crankshaft and engine block design, RA Power Solutions prepared dedicated tooling capable of grinding and polishing the crankpin of YDM4 ALCO 251 without removing the crankshaft from the engine block.

The standard diameter of the crankpin is only 152.00 mm, and the bearing width is 75.00 mm.

The details are as follows:

 

The damaged crankpin was calibrated, and excessive ovality was observed. All other parameters were found to be within limits. RA Power Solutions successfully executed the grinding and polishing of the crankpin using a portable onsite crankshaft grinding machine without removing the crankshaft from the engine block. Despite the complicated and limited inspection window opening, the repair was successfully completed; consequently, the crankpin was undersized by 2.00 mm to effectively correct the high ovality and restore proper geometry.

Onsite Crankshaft Grinding Services with Global Reach and Proven Performance

RA Power Solutions offers onsite crankshaft grinding and repair services under a wide range of conditions; whether operating on a ship at sea, at a power plant, or even at a cement plant in a remote location, the company ensures reliable and efficient solutions. As a result, this global reach ensures a quick response and, furthermore, delivers reliable solutions anywhere.Despite the complicated and limited inspection window opening, our technicians successfully completed the repair; consequently, they undersized the crankpin by 2.00 mm to effectively correct the high ovality and restore proper geometry. Furthermore, RA Power Solutions guarantees that its crankshaft grinding services ensure satisfactory performance of the crankshaft and diesel engine after repairs.

Global Expertise in Locomotive Engine Crankshaft Repair Services

With the ability to deploy skilled technicians worldwide, crankshaft repair services are available across multiple industries, including railways, marine, and power plants. As a result, this global reach ensures a quick response and, furthermore, delivers reliable solutions anywhere.

Moreover, our advanced in-situ crankshaft grinding offers significant advantages, including reduced repair time, substantial cost savings, and the complete elimination of engine removal. As a result, this technique enables efficient onsite repairs while consistently maintaining OEM standards.

 

Product Details:

A leading power plant based in Madagascar, East Africa, reported a failure of the crankshaft of a Wartsila 9L20 diesel generating set. They have multiple Wartsila DG sets of different models. They also operate Caterpillar engines.

Power plant officials were advised to open all the connecting rods and visually inspect the crankpins of the Wartsila 9L20. Damage to crankpin number #09 was reported. On going through the photographs of the damaged crankpin, the radius fillet on both sides of crankpin number #09 was observed to be damaged.

RA Power Solutions‘ two (2) technicians, along with an onsite crankshaft grinding machine, were deputed from our plant in New Delhi. The details of the engine and crankshaft are as follows:Action Taken by RA Power Solutions to Repair the Crankshaft of Wartsila 9L20 in Madagascar, East Africa

i) RA Power technicians followed a standard inspection protocol, during which the damaged crankpin number 9 was subjected to a dimensional check, crack detection by MPI, hardness check, etc. A pre-inspection report was prepared.

ii) On inspection of crankpin #09, excessive ovality of 0.41 mm was observed against the specified limit of 0.03 mm. The dimensional report is pasted below. Technicians also observed bearing line marks on the crankpin.

iii) RA Power Solutions carried out the repair by undersizing crankpin #09 of the Wartsila 9L20 by 1.00 mm, as the power plant had a 1.00 mm undersized bearing available. The engine was successfully commissioned in the presence of our technicians.

iv) The onsite crankshaft grinding machine, developed and manufactured by RA Power Solutions, is of the latest design and maintains a tolerance within 0.02 mm (20 microns) after grinding. The surface finish achieved is of a very high standard—15 RA value or less—which is highly recommended for ensuring the long life of bearings and crankshafts.
RA Power Solutions offers onsite crankshaft grinding and repair services under a wide range of conditions, whether on a ship at sea or at a power plant/cement plant in a remote location. All crankshaft grinding services provided by RA Power are guaranteed to ensure the satisfactory performance of the crankshaft and diesel engine after repairs.

RA Power Solutions is a well-known company that provides crankshaft repair, machining, and engine overhaul services on site to the marine, industrial, and power-generating sectors all over the world. The company has been in business for more than 45 years and has completed projects in Asia, Africa, Europe, the Middle East, and South America, bringing precision-engineered solutions right to clients’ premises. RA Power Solutions has powerful portable machining machines and a team of highly qualified experts. This means they can respond quickly, make repairs that are cost-effective, and do work that is as accurate as the original equipment manufacturer (OEM) anywhere in the world.

Product Details:

Cummins engine crankshaft of QSK60-G4 was damaged of a diesel generating set installed in a power plant on one of the islands in the Maldives.

The Cummins QSK60-G4 is a high-RPM engine with a compact design. The officials at the diesel power plant were informed about the damage to one of the crankpins.

The details are as follows:

 

In order to execute onsite grinding of the damaged crankpin having a standard diameter of 120.65 mm, RA Power Solutions developed special tooling that is compact and capable of grinding the crankpin and main journal of the crankshaft. Two technicians, equipped with a compact, lightweight, dedicated crankshaft grinding machine, visited Addu City, Hithadhoo Island, Maldives.

 

The following job was carried out:

i) The complete inspection of damaged crankpin number 3 was undertaken to assess the damage. The minimum and maximum sizes observed are as follows: 

• Maximum Diameter – 120.65 mm
• Minimum Diameter – 120.09 mm

The above shows an ovality of 0.56 mm, which is considered to be very high.

ii) The damaged crankpin number 3 was also subjected to MPI and hardness testing. Minor hairline marks were observed. The hardness observed was also on the higher side at a few scattered spots.

iii) The grinding of crankpin number 3 was undertaken using our specialized onsite crankshaft grinding equipment, and a final size of 119.63 mm was maintained.

 

 

 

RA Power Solutions can undertake onsite grinding of crankshafts having diameters as small as 80 mm. We can extend these services all over the world.

 

Bringing Your Cummins QSK60-G4 Crankshaft Back to Life | Fast & Reliable

The successful repair of the Cummins QSK60-G4 crankshaft shows how important it is to have specialists in situ machining for high-performance engines that work in distant places like island-based power plants. Cummins engines are recognized for being tough and well-made, but when they are damaged, such as when the crankpin is oval or the surface has flaws, they need help from experts with high-tech tools. RA Power Solutions made sure the crankshaft was put back in good operating order without taking the engine apart. This saved the client a lot of time and money.

 

 

Wherever Your Engine Is, You Can Trust Cummins Crankshaft Repair Solutions

 

RA Power Solutions has been fixing Cummins crankshafts for decades and has developed tried-and-true methods for grinding, inspecting, and restoring important engine parts on-site. Our staff provides reliable and affordable solutions around the world for Cummins diesel generators, marine engines, and heavy-duty equipment. Fixing the Cummins QSK60-G4 crankshaft in the Maldives demonstrates our skill, quick response, and dedication to keeping engines running well even in the toughest conditions.