Crankpin Bearings: A Best Component in Engine Reliability

Crankpin Bearings are precision components placed between the crankshaft and the big end of the connecting rod. They enable smooth rotation while handling heavy, cyclic loads—critical for minimizing friction, wear, and heat in the engine’s dynamic environment.
Typically made as two-piece semi-circular shells, these bearings are manufactured from multi-layer steel with specialized overlays for durability and performance.

Why Crankpin Bearings Matter — Especially in Marine & Heavy-Duty Engines

On large diesel, marine, and industrial engines, crankpin bearings:

  • Allow smooth, low-friction operation under extreme pressure.
  • Distribute loads, absorb shocks, and prevent metal-on-metal contact.
  • Help extend engine life and reduce costly downtime.

After crankshaft grinding or resizing, they often no longer fit—undersized crankpin bearings are essential in these cases. Unfortunately, such sizes are usually rare in the market, especially for older or less common engine models.

Crankpin Bearing of Yanmar Engine
Crankpin Bearing of Yanmar Engine
Crankpin Bearings of Yanmar Engine
Crankpin Bearings of Yanmar Engine

RA Power Solutions: Your Expert Source for Crankpin Bearings

With over four decades of experience, RA Power Solutions offers:

  • A wide inventory of standard and undersize crankpin bearings for major engine makes, including Yanmar, Daihatsu, MAK, MAN, and others.
  • Globally sourced tri-metal and plain bearings from Japan, Germany, and the UK
  • Custom special-size manufacturing—especially valuable when standard undersize bearings aren’t available.
  • Integration of grinding, supply, and commissioning under one provider—minimizing downtime and simplifying your project.

Types & Materials: What Makes a Crankpin Bearing Superior?

  • Design: Most are use multi-layer constructions—steel backing with copper-lead alloy substrates and wear-resistant overlays that enhance conformity and embeddability.
  • Lubrication: Bearings rely on hydrodynamic lubrication—an oil film separates moving surfaces. Poor oil supply or boundary lubrication leads to wear, cavitation, and early failure.
  • Manufacturing types: Bearings can be standard or trimmed to undersize; some advanced options include polymer or sputtered tri-component coatings for enhanced durability.
MAN B&W engine crankpin & main journal bearing undersize
MAN B&W engine crankpin & main journal bearing undersize

When Do You Need Undersize Crankpin Bearings?

  • Post-Grinding Fit
    Grinding crankshaft journals removes damage and reduces size, so standard bearings no longer fit.
  • Obsolete Engine Models
    Older or non-mainstream engines may lack available spare parts—undersize bearings become a critical solution.
  • Downtime Reduction
    Having ready-to-ship bearings saves time and keeps operations on track—critical in marine, industrial, or power generation applications.

Keep Your Engines Running: Best Practice

StrategyBenefit
Assess bearing clearance accurately after grindingEnsures proper oil film, prevents boundary lubrication
Choose the right material and layer configurationImproves load resistance, wear life, and engine reliability
Opt for suppliers with custom undersize capabilitySaves time, avoids sourcing hurdles for rare sizes
Prioritize reputable brands and tested partsReduces downtime and unexpected failures

Connect with Us for Quality Crankpin Bearings

Need reliable crankpin bearings —standard or undersized—for Yanmar, Daihatsu, MAK, MAN, or other engine makes? RA Power Solutions is your global partner, offering precision parts and expert on site support.
Email: info@rapowersolutions.com | info@rapowersolutions.com

Contact us at: +91 9582647131 or +91 9810012383

FAQs:

Q1. What are crankpin bearings?

Crankpin bearings are precision components that support the connecting rod on the crankshaft, reducing friction and wear.

Q2. Why are undersize crankpin bearings needed?

These are required after crankshaft grinding when journal diameters are reduced.

Q3. What causes crankpin bearing failure?

Improper lubrication, high loads, or misalignment are the most common causes of crankpin bearing failure.

Q4. Can custom-size of Bearings be manufactured?

We manufacture custom undersize and special bearings for obsolete or rare engine models.

Q5. Which engines commonly use ?

Marine, industrial, and power engines such as Yanmar, Daihatsu, MAK, and MAN.

What Is Metal Stitching and Metal Locking? A Trusted Cold Repair Technique: RA Power Solutions

When a metal component cracks—especially in large equipment like engine blocks, compressors, or turbines—repair options can be costly, time-consuming, and risky if not done correctly. One highly effective method that avoids heat, preserves alignment, and restores structural integrity is metal stitching, also known as metal locking.

Understanding Metal Stitching

Metal stitching is a cold mechanical repair process used to fix cracks or breaks in cast metals such as cast iron, aluminum, steel, and bronze. Unlike welding, which uses high heat, metal stitching relies on precision-drilled holes, specially designed stitching pins a nd locks to seal and reinforce the damaged area.
This technique is ideal for industrial applications where heat could distort components or where disassembly isn’t feasible.

Metal stitching under process
Damaged Crankshaft before metal stitching

How the Process Works

Here’s a simplified breakdown of how metal stitching is done:

  • Crack Detection: Identify and inspect the full extent of the crack.
  • Drilling Pattern: A series of holes is drilled along and across the crack.
  • Slot Cutting: A slot is formed to fit stitching locks or keys.
  • Installing Locks: Metal locks are inserted into the slots to mechanically bind both sides of the crack.
  • Threaded Studs: In some cases, overlapping threaded studs are used to seal the crack.
  • Sealing & Finishing: The surface is peened and machined smooth to match the surrounding area.
Metal Loking of Engine Block
Onsite Metal Locking under process

Why RA PowerSolutions?

At RA PowerSolutions, we specialize in on site metal stitching and metal locking for all types of cast components. There is no need for dismantling or transporting the part.
With decades of experience and hundreds of successful global repairs. We help industries reduce downtime, avoid expensive replacements, and restore strength and performance efficiently.

Our services include:

  • Metal stitching of engine blocks, compressors, pumps, etc.
  • On site machining and grinding
  • Repair of crack-prone components like turbine casings and gearbox housings
  • ISO-certified technicians and portable tools
Metal Stitching of Engine Block

If you’re facing a critical breakdown or seeking long-term solutions for metal cracks, RA PowerSolutions is ready to assist with expert, onsite support. Contact us today to learn more or schedule an inspection.

For more details on the Metal Stitching and Metal Locking , Crack Repair by Metal Stitchng email us at info@rapowersolutions.com. Call at +91-9582647131,+91 9810012383.

FAQs:

1. What is metal locking?

Metal locking crack repair process – Metal-lock or metal stitching is a method of repairing fractures to castings, onsite without the use of heat. It involves sinking Metal-lock keys, perpendicular to a fracture. The fracture is then sealed and held rigid by Metal-lace studs

2. How is metal stitching better than welding?

Metal stitching does not use heat, so there’s no distortion or weakening of the material. It preserves the original shape and alignment of the part and is ideal for cast iron, which is prone to cracking when welded.

3. Can metal stitching be done on-site?

Yes, RA Power Solutions specializes in on site metal stitching, allowing us to repair damaged equipment without dismantling or transporting it—saving time, cost, and downtime.

CRANKSHAFT GRINDING AND REPAIRING

At RA Power Solutions, we deliver expert crankshaft grinding and repair services for marine engines, automotive engines, industrial machinery, pumps, and compressors. Our precision machining ensures optimal performance, extended lifespan, and reliable operation of your critical equipment.

Crankshaft Machining Expertise

The crankshaft is the backbone of engines and rotating machinery, comprising the main journal and crank pin. Our specialized grinding and polishing services restore these components to OEM specifications, ensuring smooth operation and durability.

Crankshaft Grinding Under process

Rigorous Inspection & Quality Assurance

Every crankshaft undergoes comprehensive testing before and after repair to guarantee safety and performance. Our inspection process includes:

  • Magnetic Particle Inspection (MPI) – Detects surface and near-surface flaws
  • Hardness Testing – Ensures material integrity
  • Surface Roughness Testing – Verifies optimal finish for reduced friction

Precision Grinding & Polishing

Our advanced grinding and polishing services deliver:

  • High dimensional accuracy
  • Superior surface finish
  • Strict adherence to OEM tolerances

Polishing removes bearing line marks and enhances surface quality for smoother operation.

Crankpin Polishing Onsite

Advanced Workshop Capabilities

Our state-of-the-art machine shop handles diverse crankshaft repairs, including:

  • Crankshaft straightening
  • Seal area rebuilding (using sleeves or metal spray technology)
Crankpin Polishing Onsite
After Grinding and Polishing of Crankpin

Our Crankshaft Services Include:

Trust RA Power Solutions for precision-engineered solutions that maximize performance and reliability.

Metal Stitching And Metal Locking Services For Crack Cast Iron Repairs | Global Leaders

RA Power Solutions specializes in metal stitching and metal locking, offering a trusted and effective solution for repairing cracked or damaged cast iron components. Unlike traditional welding, which can cause heat-induced stress and distortion, our cold repair techniques ensure structural integrity without compromising the original material properties.


What is Metal Stitching and Metal Locking?

Metal stitching and metal locking are specialized cold repair techniques used to restore cracked or damaged cast iron and other metal components without welding or heat application. These methods are widely used in industries where heat-based repairs could cause further damage, distortion, or weakening of the material.

Metal Stitching
Metal stitching is a mechanical repair process that joins broken metal parts by inserting precision-engineered metal stitches along the crack. These stitches restore the strength and integrity of the component while keeping the original structure intact. The process involves:

  • Drilling holes along the crack in a controlled manner.
  • Connecting the holes with a milled slot to create a secure stitching channel.
  • Installing metal stitches or keys that pull the broken sections together, creating a seamless repair.

Metal Locking
Metal locking is an advanced reinforcement technique that works alongside metal stitching. And Enhance the repair’s strength. It involves placing metal locks perpendicular to the crack to distribute stress evenly, preventing further damage. This makes the repair permanent, durable, and capable of withstanding high loads and pressure.

Metal Stitching Under Process

Why Choose RA Power Solutions?

  • 44+ Years of Experience – The only company in India with decades of expertise in metal surgery, metal locking, and metal stitching.
  • Onsite Repairs – No need to dismantle heavy machinery; we repair components at your location, minimizing downtime.
  • Global Reach – Our team has successfully completed over 1000 crack repair projects worldwide, serving industries across various sectors.
  • Trusted by Leading Companies – Major corporations in India and internationally rely on us for cost-effective and high-quality repairs of heavy cast iron components.

At RA Power Solutions, we use portable and lightweight equipment, allowing our skilled technicians to provide onsite repair services at any plant or site in India and worldwide. With over 44 years of experience, we are the only company in India. With a proven track record in metal locking and metal stitching. Our expertise has made us a trusted partner for major companies globally.

Metal Locking

Leading industries in India and across the world rely on our services. For crack repair and restoration of heavy cast iron components.
For more information on metal stitching service providers, metal stitching, cast iron stitching, or cracked engine block repair. please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs

What is the metal locking process?

The metal locking process is a mechanical repair method used to fix cracks or breaks in metal components without welding. It involves inserting metal locks and pins to restore structural integrity, making it ideal for cast iron or machinery repairs where heat from welding is not suitable.

How does metal stitching work?

We repair cracked metal by using special stitching pins. These pins are carefully installed by drilling and tapping along the crack, pulling the sides together. This creates a strong, interlocking row of pins that seals the crack and restores pressure-tight strength.

What is the best way to repair cracked metal?

At RA Power Solutions, we use several proven methods to repair cracks commonly found in engine components. The most popular techniques include:
Tapping and Plugging – Sealing the crack by inserting metal plugs to restore strength and prevent leakage.
Sealants – Applying industrial-grade sealants for minor cracks that don’t require heavy machining.
Sleeve Insertion – Fitting a strong metal sleeve to reinforce and protect the damaged area.

How to do metal stitching?

Holes are carefully drilled along the length of the crack, then tapped and filled with special stitching studs. Each stud overlaps slightly with the previous one, creating a tight, pressure-resistant seal. This is the core step of the metal stitching process, where the crack is effectively replaced by a solid row of studs. After installation, the surface is peened for added strength, and any excess material is smoothly ground off.

What is cold metal stitching?

Metal stitching is a mechanical repair method where we carefully drill and tap along the length of the crack, then insert special interlocking stitching pins. This creates a strong, pressure-tight seal—without the need for heat or welding.

Wartsila 4L20 Crankshaft Repair on Board a Vessel

The Wartsila 4L20 crankshaft was repaired by RA Power Solutions technicians on board a vessel while sailing. The vessel is owned by a reputed shipping company based in kuwait. Due to the serious accident the crankshaft was removed from the engine block as the crankcase of Wartsila 4L20 was also badly damaged beyond repair.

The main dimensions of the crankshaft of Wartsila 4L20 are as follows:

S. NOCrankshaft Details
1.Engine MakeWartsila
2.Engine Model4L20
3.Crank pin Diameter Standard180 mm
4.Crankpin Bearing Width71 mm
5.Main journal diameter210 mm
6.Place of execution of crankshaft repairSailing from Paradip Port to Ennore Port India
Wartsila 4L20 damaged crankshaft
Wartsila 4L20 damaged crankshaft
Damage crankpin of Wartsila 4L20
Damage crankpin of Wartsila 4L20

Action taken by RA Power Solutions technicians to repair the Wartsila 4L20 Crankshaft

  • On arrival our technicians observed that the damaged crankshaft was lying on the floor. A design of v block was made and V block was manufactured on the vessel. This was done to do the inspection & grinding of the crankshaft as it was aleady removed from the engine block.

RA Power has a tooling by which crankpin grinding can be done without removing the crankshaft from the block

  • All four crankpins were inspected. The maximum ovality of 0.17 mm was observed.

Inspection report is pasted below:

SIZE OF CR BEFORE GRINDING

  • Uneven surface, bearings line marks and pitting marks were observed on all crankpins.
  • All main journals were also dimensionally checked and were observed to be within limits. The standard diameter of the main journal is 210 mm.
  • As a matter of routine hardness test, crack detection test, surface finish test etc was done and observed within limits.
  • The grinding of damaged crankpins was done and all the crankpin were undersized by 0.50 mm only. The final size of the crankpin was maintained between 179.48 to 179.50 mm.
Wartsila 4L20 crankshaft grinding on V-BLOCK
Wartsila 4L20 crankshaft grinding on V-BLOCK
Crack detection test of Wartsila 4L20 Crankshaft before grinding
Crack detection test of Wartsila 4L20 Crankshaft before grinding

The final diameter maintained after grinding of crankpins is pasted below:

SIZE OF CR AFTER GRINDING

Crankpin Polishing after inspection of crankshaft
Crankpin Polishing after inspection of crankshaft

The above job was done while sailing of the vessel from Paradip port to Ennore port India and there was no need of stopping the vessel.

We have been regularly executing the repairs in Madagascar, Oman, Qatar, Philippines, Bahrain, Srilanka, Bangladesh, Myanmar, Turkey, Nigeria, Greece, Saudi Arabia, UK, Dubai, Malta, Cyprus, Singapore, Malaysia, Colombia, Indonesia, Hong Kong, Spain, Netherlands, Dubai, Portugal, Estonia, Morocco, Belgium, Vietnam, Canada, Jordan, Libya, Kuwait, Egypt, Morocco, Yemen, Bahrain, Tunisia, Sudan, Oman, Algeria, UAE, Iraq.

Wartsila 4L20 Engine Crank pin after Grinding
Wartsila 4L20 Engine Crank pin after Grinding
Wartsila 4L20 crankpin after grinding & polishing
Wartsila 4L20 crankpin after grinding & polishing

For more informationon Wartsila 4L20 Crankshaft Repair, contact us on rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Daihatsu 5DK-20 Crankshaft Repair | RA Power Solutions Forty-Five Years Of Experience

Daihatsu 5DK-20 crankshaft has been successfully repaired by RA Power Solutions technicians on board a vessel recently. A leading shipping company based in Greece operating more than fifty container vessels approached RA Power Solutions to repair the crankshaft of Daihatsu 5DK-20 on the vessel.

The main challenge was that the crankpin no. 03 of Daihatsu 5DK-20 met with a serious accident damaging the radius fillet of both sides of the crankpin. They had a stopover of only 18 hrs at Mundra Port India.

In fact, the owners disparately tried to get the crankpin repaired in Dubai and approached leading companies but none of them was able to repair the crankpin with a damaged radius filet.

Major Technical Details Of Daihatsu 5DK-20 Crankshaft

S. NOCrankshaft Details
1.Engine MakeDaihatsu
2.Engine Model5DK-20
3.Crankpin Diameter Standard170 mm
4.Crankpin Bearing Width78 mm
5.Place of execution of crankshaft repairMundra Port India
Before grinding and polishing of Daihatsu 5DK-20 crankshaft
Picture Showing Before Grinding and Polishing of Daihatsu 5DK-20 crankshaft
Crankshaft grinding of Daihatsu 5DK-20
Crankshaft grinding of Daihatsu 5DK-20

Action taken by RA Power Solutions for successful repair of Daihatsu 5DK-20 Crankpin

  • Dimensional inspection of the crankpin no. 03 was done by the technicians and an ovality of 0.49 mm with deep bearing marks, rough surface, etc was observed.
  • The radius fillet of both sides of crankpin no. 03 was damaged badly in fact the original profile of the fillet radius of Daihatsu crankshaft was lost due to an accident.
  • Hardness and crack detection tests were undertaken and were found within limits.
  • Deflection was also within the parameters.
  • Our technicians with the help of specially designed compact dedicated tooling for repair of crankpin having small bearing width used the equipment. They reduced the diameter of the crank pin by 1.0 mm and maintained the final diameter of 169.00 mm. Maintaining the tolerance within 0.02 mm, the preparation & formation of radius fillet on both sides of the crank pin was a challenge which was done by our technicians within 18 hours of boarding the vessel.
  • In this case of Daihatsu 5DK-20 the crank pin bearing width is only 78 mm and with our specially designed equipment it was possible to undertake the grinding.No other company have the compact tooling to undertake such repairs on site without removing it from the engine block.
  • The bearing is only 1.0 mm undersize and was supplied by RA Power Solutions. The engine was commissioned during the presence of our technicians on board the vessel.
Daihatsu 5DK-20 after Grinding & Polishing
Daihatsu 5DK-20 after Grinding & Polishing
Crankpin Daihatsu 5DK-20 after Repair
Crankpin Daihatsu 5DK-20 after Repair

RA Power Solutions is ISO 9001:2015 (Quality Management System) & ISO 14001:2015 (Environmental Management System) certified approved company.

We have been regularly executing onsite crankshaft repairs and crankshaft grinding in Dubai, Oman, Saudi Arabia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, and Fujairah, Bahrain, Kuwait, Iraq, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

For more details of the Repair of engine and supply of bearings, Daihatsu 5DK-20 Crankshaft repair please email us on rajshahani@rapowersolutions.com, info@rapowersolutions.com or Call us at +91 9582647131, or +91 9810012383.

Save Daihatsu DC-17 Crankshaft From Rejection | Forty Five Year’s Expertise

Contact RA Power Solutions for undertaking the Daihatsu DC-17 crankshaft repair and all models without removing the crankshaft from the block.

MAJOR TECHNICAL DETAILS OF DAIHATSU DC-17 :

S. NOCrankshaft Details
1Engine MakeDaihatsu
2Engine Model6DC-17 Engine
3Crankpin Diameter Standard145mm
4Crankpin Bearing Width64mm
5Place of execution of crankshaft repairOdisha Port India
Repair of Crankpin of Daihatsu DC-17
Repair of Crankpin of Daihatsu DC-17
Crankshaft Grinding of Daihatsu DC-17 Engine
Crankshaft Grinding of Daihatsu DC-17 Engine

As can be seen from the above the crankshaft of Daihatsu DC 17 crankpin width is only 64 mm and diameter is 145 mm which is considered to be very small. It requires a very compact design of Insitu crankshaft grinding machine which can be inserted from the engine block.

RA Power Solutions is the only company in the world which has the latest technology, Equipment, and process available for crank pin grinding and polishing of Daihatsu DC-17 without removing it from the engine block. The grinding of crankpin can also be done while sailing of the vessel.

Machining of crankshaft of Daihatsu DC-17
Machining of crankshaft of Daihatsu DC-17
Grinding under Process of Daihatsu DC-17
Grinding under Process of Daihatsu DC-17

Save Crankshaft of Daihatsu DC-17 contact RA Power Solutions for successful and Guaranteed repair

  • Since no other crankshaft repair company in the world has equipment, technology, and process available for repair of the crankshaft of Daihatsu DC17, they insist on removing it from the block and sending it to the workshop or rejecting it by giving some excuses.
  • Contact RA Power Solutions who have forty-five years of experience in onsite crankshaft grinding and have successfully repaired more than hundred crankshafts of Daihatsu DC-17 all over the world.
  • The reference of that client, certificate of satisfactory performance, and inspection reports signed by chief engineers of the vessel can be furnished on request.
  • Reduce downtime, and save crankshaft by getting it repaired by RA Power Solutions.
  • Undersize bearings of all sizes of crank pin are available in our stock.

RA Power Solutions is ISO 9001:2015 (Quality Management System) & ISO 14001:2015 (Environmental Management System) certified approved company.

We have been regularly executing onsite crankshaft repairs and crankshaft grinding in Dubai, Oman, Saudi Arabia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, and Fujairah, Bahrain, Kuwait, Iraq, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

Crankpin of Daihatsu DC-17 Engine Crankshaft after Repair
Crankpin of Daihatsu DC-17 Engine Crankshaft after Repair
Crankshaft Grinding of Daihatsu DC-17
Crankshaft Grinding of Daihatsu DC-17

For more details on the Repair of the engine please email us at raj.shahani@rapowersolutions.com, info@rapowersolutions.com or Call +91-9582647131,+91 9810012383.

Cylinder Liners Manufacturer | RA Power Solutions | 4 Decades of Expertise

RA Power Solutions with forty-five years of presence in the field of high-capacity engine spare parts and repairs understand that the cylinder liners are the most critical part of the engine where actual combustion takes place. The cylinder Liners for the main and the auxiliary engines are normally manufactured out of cast iron.

Cast Iron Cylinder Liner
Cast Iron Cylinder Liner

Manufacturing Range of Cylinder Liners

  • Our Present range of cylinder Liners is up to 700 mm bore with a length of 1200 mm. These parameters cover most of the popular engines and their models.
  • The liners are manufactured by us as per the drawing provided by the clients. We also develop and manufacture cylinder liners as per the sample provided by the clients.
  • We have developed a large number of liners which are not available in the market because of the closure of the manufacturing units.
  • The customers in the absence of non-availability of cylinder liners face a lot of problems. We can develop & manufacture the Cylinder Liners Manufacturer in a short duration and at very competitive rates.
Cylinder Liner Manufacturer
Cylinder Liner Manufacturer
Cylinder Liner for forging equipment
Cylinder Liner for forging equipment

Quality of Cylinder Liners

All the cylinder Liners are manufactured by a centrifugally cast process in order to have the uniform grain structure of the casting. The alloy cast iron cylinder liner gives high wear and corrosion resistance with durability and long life. The liners are finely machined and ground. For honing the latest equipment is used to maintain the desired finish and parameters.

We have been manufacturing and exporting the cylinder liners to leading companies all over the world including Argentine, Brazil, Czech Republic, Peru, Bolivia, Russia, Germany, United Kingdom, France, Italy, Spain, Paraguay, Poland, Romania, Netherlands, Belgium, Czech Republic, Greece, Portugal, Sweden, Hungary, Belarus, Austria, Serbia, Bulgaria, Denmark, Finland, Norway, Ireland, Slovenia, Estonia, Malta, Jordan, Libya, Kuwait, Egypt, Morocco, Yemen, Bahrain, Trinidad and Tobago, Tunisia, Sudan, Oman, Algeria, Saudi Arabia, Iraq, Venezuela, UK etc.

For more information on Cylinder Liners Manufacturer, and cylinder liners exporter contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

Cylinder Liner for CKD Skoda Engine
Cylinder Liner for CKD Skoda Engine
Cylinder Liner for auxiliary engine
Cylinder Liner for auxiliary engine

Insitu Machining of Sulzer Z 40/48 Crankshaft on vessel | Sulzer Crankshaft Repair

A Sulzer main engine Sulzer Z 40/48 aboard a container vessel faced serious damage to the crankshaft due to failure of the Governor, this resulted in damage to crankpins.

The major technical details of Sulzer Z 40/48 crankshaft are given below:

S. No.Crankshaft Details
1.Engine MakeSulzer
2.Engine ModelZ 40/48
3.Crankpin Diameter Standard330 mm
4.Crankpin Bearing Width132 mm
5.Place of execution of crankshaft repair Port of Las Calderas Bani in Dominican Republic
Damaged crankpin of Sulzer Model Z 40/48
Damaged crankpin of Sulzer Model Z 40/48
Repair of Crankshaft of Sulzer Model Z 40/48
Repair of Crankshaft of Sulzer Model Z 40/48

The inspection of the Sulzer crankshaft was done by our technicians and the following main observations were reported.

  • On removal of the connecting rod from all the six crankpins the crankpin bearings were observed badly damaged. There were deep scoring marks and localized damage on the crankpin.
  • The hardness and crack detection was done and they were observed to be within limits.
  • Deflection readings were within the parameters stipulated in the manual.
  • The crankpins dimensional were checked and ovality as per following table was observed.
main observations were reported
Sulzer Model Z 40/48 crank pin no 04 before grinding
Sulzer Model Z 40/48 crank pin no 04 before grinding
Crankpin no. 05 of Sulzer Z 40/48 before grinding
Crankpin no. 05 of Sulzer Z 40/48 before grinding
Sulzer Model Z 40/48 crank pin no 06 before grinding
Sulzer Model Z 40/48 crank pin no 06 before grinding

Action taken by RA Power Solutions for successfully repair of crankshaft Sulzer Z 40/48

  • The ovality, deep scoring marks and local damage was observed on all crankpins, further the ovality ranging from 0.11 mm to 0.43 mm was observed as per the dimensional chart pasted above.
  • In this situation client’s management was consulted and a presentation was made on the damage to the crankshaft and the remedial action proposed by RA Power Solutions.
  • All the crankpins were undersized as per the chart below except crankpin no 01 which was only polished:
Action taken by RA Power Solutions for successfully repair
  • The radius fillet of two crankpins which were damaged due to the accident was also repaired.
  • After repair technicians again checked all the parameters and were found within limits.

Sulzer Model Z 40/48 crankpin repair results

RA Power Solutions experienced technicians repaired the crankshaft successfully within the tolerance limits specified in the manual and then re- install the crankshaft to full rated capacity of the load.

By undertaking the repairs of the crankshaft onsite without removing it from the engine block, clients save the down time and also the cost of removing it from the block and sending it to the workshop.

Crankpin no. 03 after grinding & polishing on board a vessel
Crankpin no. 03 after grinding & polishing on board a vessel
Sulzer Z 40/48 Crankpin after successful repair
Sulzer Z 40/48 Crankpin after successful repair
Sulzer engine Z 40/48 Crankpin no. 05 after repair
Sulzer engine Z 40/48 Crankpin no. 05 after repair

RA Power Solutions is ISO 9001:2015 (Quality Management System) & ISO 14001:2015 (Environmental Management System) certified approved company and extends crankshaft repair services all over the world. We can move our team of technicians and equipment anywhere in the world within 24 hours of first information.

We have been regularly executing on-site crankshaft repairs and crankshaft grinding in Dubai, Oman, Saudi Arabia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, and Fujairah, Bahrain, Kuwait, Iraq, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

For more details of the Repair of engine, Engine Sulzer, please email us on raj.shahani@rapowersolutions.com, info@rapowersolutions.com or Call +91 9582647131, +91 9810012383.

Compressor Crankshaft Grinding and Polishing Onsite

RA Power Solutions was approached by a leading Fertilizer producing company based in north India regarding the requirement of onsite grinding and polishing of compressor crankshaft.

The company has five high-capacity CO2 compressors which have been imported from a leading company based in Europe.

Our team consisting of three technicians along with onsite crankshaft grinding equipment was deputed to the site and following was observed:

Details of CO2 Compressor Crankshaft:

S. NOCrankshaft Details 
1Engine Make/ Model CO2 COMPRESSOR
2Crankpin Diameter Standard 317.30 MM
3Crankpin Bearing Width 210.00 MM
4 Main Journal diameter 330 mm & 317.30 mm
5Main Journal Width 370 mm & 225 mm
6 Place of execution of crankshaft repairFertilizers & Chemicals Plant in India
  • On dimensional inspection of crankpin it was observed that crankpin nos. 02 developed excessive ovality. It also had deep line marks due to the failure of bearings which are of babbitt white metal type.
  • All the remaining crankpins were inspected and rough surfaces including bearing line marks were observed.
  • The main journal having a standard diameter of 330 mm also had a rough surface and required polishing.
Damage crankpin of CO2 Compressor
Damage crankpin of CO2 Compressor
Damage of crankpin no. 6 of Compressor
Damage of crankpin no. 6 of Compressor
Onsite repair of damaged crankshaft of CO2 Compressor
Onsite repair of damaged crankshaft of CO2 Compressor
Picture showing before polishing of Main Journal
Picture showing before polishing of Main Journal

Action taken by RA Power Solutions

Considering the fact that the main journal having a diameter of 330 mm having a rough surface and bearing line marks it was decided to remove the crankshaft from the compressor.

RA Power Solutions technicians submitted a drawing of V-Block which were manufactured in the factory for placement of crankshaft.

The grinding of crankpin no. 02 was undertaken and the final dimensions were maintained between 315.58 mm to 315.60 mm. The ovality of only 0.02 mm was observed.

All the remaining 05 crankpins were polished, removing the line marks and improving the surface finish. The surface finish after polishing was observed at less than 15 RA value.

All the main journals were also polished onsite removing the ovality to some extent and improving the surface finish again to less than 15 RA value.

Crack detection test of compressor crankshaft before grinding
Crack detection test of compressor crankshaft before grinding
CO2 Compressor Crankshaft Inspection and Repair on site
CO2 Compressor Crankshaft Inspection and Repair on site

Advantage of getting the crankshaft grinding/ Polishing done by RA Power Solutions

  • RA Power Solutions is the only company in India having experience of forty-three years in crankshaft repair.
  • We have ready availability of equipment up to 700 mm diameter. The equipment is portable and lightweight and can be taken to any site all over the world as accompanied baggage. The modification in the onsite crankshaft grinding and polishing equipment is possible as per the site requirement.
  • In this case since the main journal diameter was to be polished the V-Block was designed and fabricated onsite.
  • RA Power Solutions as a protocol undertakes all the checks prior to grinding and polishing like cracks by MPI, Hardness test, deflection, etc.
  • We also manufacture babbitt white metal bearings and do rebabbitting of old bearing up to 1500 mm diameter.
After Grinding and polishing taken deflection of CO2 Compressor Crankshaft
After Grinding and polishing taken deflection of CO2 Compressor Crankshaft
Main Journal of CO2 compressor after polishing
Main Journal of CO2 compressor after polishing

For more information on crankshaft grinding services, insitu crankshaft grinding and polishing, onsite crankshaft repair, or crankshaft polishing services email us at rajshahani@rapowersolutions.com, info@rapowersolutions.com Call at +91 9582647131,+91 9810012383.