INSTRUCTIONS

Wärtsilä 4-stroke 4611Q003

Technical Services Issue 3, 25 October 2017

Reconditioning of crankshafts
For your information

Internal within Wärtsilä Network. Engines concerned

The document and related measurement records can WÄRTSILÄ® 46, 46GD, 50, 50DF and
be given to customers when needed. 50SG engines.

Reference
11 Crank mechanism
WS11Q001 Reconditioning procedures of
crankshafts

Introduction
The purpose of this document is to
summarise the conditions and provide
detailed instructions for the in situ
recondition actions, which can be taken on
the crank pin or the journal of a crankshaft.

Validity / Issue
Until further notice. Replacing issue 2 dated
24.3.2003.

Update in issue 3:
· Additional engine types included
· Available bearings updated
· Verification added

Note
Technical Services must be consulted
regarding:
· High hardness reading
· Crack depth
· Exceptional run-out

Wärtsilä Finland Oy Services Switchboard Tel: +358 10 709 0000

P.O. Box 252 (Tarhaajantie 2)
FIN-65101 Vaasa, Finland
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4611Q003, Issue 3, Page 2 / 10

Contents
Page
1 Introduction 2
2 Pre-inspections 2
3 Reconditioning 6
4 Post-inspections 9
5 Assembly 9
6 Flushing 10
7 Start-up 10
8 Verification 10

1 Introduction
The purpose of this document is to summarise the conditions and provide detailed
instructions for the in situ recondition actions, which can be taken on the crank pin or the
journal of a crankshaft. The crankshaft of WÄRTSILÄ ® 46 and 50 engines are non-
hardened. Experience has shown that a vast majority of bearing failures are due to
malfunctions in the lubricating oil system.

CAUTION:
The alarms on lubricating oil system should never be ignored or by-passed.
The reason for the alarm condition should always be determined and the cause rectified
prior to continuing to run/re-start.

The markings stamped on the web of the first cylinder should always be recorded before
reconditioning, see Figure 1.

Figure 1, Markings on the crankshaft

2 Pre-inspections
This chapter sets the criteria and priorities in checking the condition of crankpin and main
journal.

2.1 Deflection and radial run-out

2.1.1 Big end bearing / crank pin damage
The deflections and circular run outs can be checked according to the Figures 2 and 3
on page 3. Run out readings more than 0.2 mm are not exceptional after bearing
damage.
One journal at a time to be checked for max. run-out.
Measurement Records:
· WV11V056 Crankshaft run-out
· 4611V005 Crankshaft deflection
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Figure 2, Preferred dial calliper positions for initial checks of a damaged crank pin (D.P.)

Figure 3, Alternative principle for the run-out checks

2.1.2 Main journal damage

Figure 4, Deflection and radial run-out checks in case of main bearing failure (D.M.J)
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2.2 Cracks
After a bearing failure, the bearing material remnants are to be cleaned from the pin
surface. A magnetic particle examination is to be performed on the pin in question. All
the cracks must be ground out (=removed). The depth of cracks can be evaluated based
on the premise, that the depth of a crack is normally about 20% of its length.
Try to locate the deepest cracks, since these set the criteria for reconditioning or
replacement.
Measurement Record:
· 4611V012 Crankshaft hardness/cracks

2.3 Material hardness

Hardness readings higher than 450 HB call for further actions. See chapter “Post-
inspections”, for hardness limits.
A heat treatment for reducing the hardness to be applied on a damaged pin.
Measurement Record:
· 4611V012 Crankshaft hardness/cracks

2.4 Mechanical wear

Wear of crankshaft journals or pins can occur as a consequence of long time operation
under unfavourable conditions, for example with contaminated lubricating oil. Should one
of the wear limits (see Table 1 on page 5) be reached, re-machining to the next standard
undersize dimension of the respective journal or pin is necessary.

Figure 5, Measuring points

If all measurements are within the limits but there is still doubt about the general state of
the surface, checking with marking blue should be carried out. For instructions on how
to perform the check, see chapter “Post-inspections”.

NOTE:
Wear of crank pins normally takes place between the webs.

Measurement Record:
· 4611V013 Crank pin and main journal dimensions & surface roughness
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Table 1, Wear limits (referred to diameter), see Table 2 for interpretations

Journal (mm) Crank pin (mm)

O Circularity max. 0.060 0.080
Cylindricity max. 0.050 0.050
// Parallelism max. 0.050 0.050
Circular Run-out max. 0.060 0.060
Diameter max. 0.120 0.160
Table 2, Geometrical tolerances

Symbols and Examples of indication and interpretation

tolerance Tolerance zone Indication on Interpretation
characteristics drawing

The circumference of
each cross-section shall
Circularity be contained between
two co-planar concentric
circles 0.1 apart

The considered surface

shall be contained
Cylindricity
between two coaxial
cylinders 0.1 apart

The tolerance axis shall

Parallelism
be contained in a
of a line
cylindrical zone of
(axis) with
diameter 0.1, parallel to
reference to
the datum axis A
a datum line
(datum line)

The radial run-out shall

not be greater than 0.1 in
Circular
any plane of
Run-out
measurement during one
radial
revolution about the
datum axis AB
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3 Reconditioning
ATTENTION:
Ensure that bearings are well lubricated when rotating the crankshaft during following
activities.

3.1 Polishing
A journal or a crank pin with a roughened surface, but with the dimensions still within the
limits, should be polished. However, polishing should generally not be carried out by
hand with emery and polishing paper. Instead, a polishing device should be applied as
provided by established specialized firms.

ATTENTION:
Prior to performing any machining the radiuses are to be checked and made concentric
with the pin or journal.

Measurement Record:
· 4611V013 Crank pin and main journal dimensions & surface roughness

3.2 Heat treatment

Heat treating a crank pin to reduce hardness also reduces the amount of re-machining
and makes the machining work easier. It also eliminates in many cases the need for
straightening by traditional methods.
The heat treatment is to be made carefully in a well-controlled manner and below the
original tempering temperature of the shaft, so that there is no influence on the basic
mechanical properties of the shaft.
Following the treatment the hardness is typically reduced by 200 HB ± depending on the
original status of the pin. However, not more than to the initial hardness of the shaft
material. The hardness deviation is reduced as well.
Please contact Wärtsilä Technical Service for further details.

3.3 Re-machining
Re-machining of an individual journal or crank pin should be carried out according to
Figures 6 (in-line) and 7 (V-configuration) and Tables 3 and 4.
Table 3, Diameters for undersized crank pins

Bearing
-0.5 -1.0 -1.5 -2.0 -3.0 -4.0 -5.0 -6.0 -7.0 -8.0 -9.0 -10.0
(mm)
Undersize 442.00 441.00 440.00
449.50 449.00 448.50 448.00 447.00 446.00 445.00 444.00 443.00
Ød *) *) *)

Diameter to tolerances for all undersized crank pins: 0

-0.060
*) Check the influence on torsional vibrations with Wärtsilä Services prior to machining
Table 4, Diameters for undersized journals

Bearing (mm) -0.5 -1.0 -1.5 -2.0 -3.0 -5.0

Undersize ØD 449.50 449.00 448.50 448.00 447.00 445.00
Diameter to tolerances for all undersized journals: 0
-0.060
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AB

CD

x): AB = Datum axis is the centre line of adjacent journals,

see fig. 1.
xx): CD = Datum axis is the centre line of adjacent journals,
see fig. 2.
xxx): Turn the shaft to the direction of rotation without
stopping.
a) Measure simultaneously at both ends of one and the
same journal. Maximum difference in readings:
0.10mm
b) The reading of both dial callipers must not exceed
0.20mm
xxxx): Dimensions in brackets are for engines built before
1996.

The maximum non-bearing area is Ø 80mm.

After re-machining, the transitions between running

surface and lubricating oil holes have to be rounded off
and polished (Ra =1.6)

Figure 6, Re-machining of crank pins and journals of an in-line engine

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AB

CD

x): AB = Datum axis is the centre line of adjacent

journals, see fig. 1
xx): CD = Datum axis is the centre line of adjacent
journals, see fig. 2.
xxx): Turn the shaft to the direction of rotation
without stopping.
c) Measure simultaneously at both ends of
one and the same journal. Maximum
difference in readings: 0.10mm
d) The reading of both dial callipers must not
exceed 0.20mm
xxxx): Dimensions in brackets are for engines built
before 1996.

The maximum non-bearing area is Ø 80mm.

After re-machining, the transitions between

running surface and lubricating oil holes have to
be rounded off and polished (Ra =1.6)
Figure 7, Re-machining of crank pins and journals of a V-engine
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4 Post-inspections
The quality of a pin or journal after machining has to meet the following requirements.

4.1.1 Geometrical tolerances

Geometrical tolerances in accordance with Figure 6 (in-line engines) or Figure 7 (V-
engines).

4.1.2 Blueing check

A check with marking blue is recommended to be carried out on the re-machined surface.
Use straight ruler to see equal contact across the bearing area.

4.1.3 Crack testing

Free of hairline cracks: Journal or crank pin to be tested by means of magnetic particle
crack detection method (afterwards de-magnetizing).
The surface must be free of any cracks after re-machining. A small individual crack may
be ground out on the ground/re-machined surface. Transition to the surface is to be
rounded off.

4.1.4 Hard spots on surface

Even after re-machining a journal or a crank pin the same may have local hard spots left
over as a result of the bearing failure.
Such local spots can be tolerated as long as they are not found around or at recesses
and at the bores for lubrication.
Maximum admissible hardness of remaining local hard spots is 450HB. However around
the recesses, 80 mm from the web, or at the lubrication bores, Ø 80 mm, the hardness
of 350HB should not be exceeded.

Measurement Records:
· 4611V005 Crankshaft deflection
· 4611V012 Crankshaft hardness/cracks
· 4611V013 Crank pin and main journal dimensions & surface roughness
· WV11V056 Crankshaft run-out

5 Assembly
Follow the instructions given in the engine instruction manual. Ensure that bearing shell
halves of the correct type are mounted.
If the crankshaft is machined to undersize:
· Ensure that bearing shell halves of the correct undersize are mounted.
· Install a sign plate on the engine block where the ground crank pin / main journal /
thrust bearing is with a note:
Crank pin No. ___ is ___ mm undersize.

Main journal No. ___ is ___ mm undersize.

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6 Flushing
After reconditioning, all dirt, residue or any contaminating material must be removed from
the sump. The whole lubricating oil system must then be flushed according to the
following main principles:
· Clean the oil sump and tank.
· Clean the oil pipe lines.
· Clean filter, coolers, and temperature control valves and check condition of the gravity
tank.
· Flush with low viscosity oil or engine oil (min. temperature 60°C).
· Flush first the whole external oil circuit without the engine. Connect an additional pipe
before engine inlet and led it straight to engine oil sump.
· Connect oil pipe to the engine inlet, lower main bearing hydraulic jacks down, blind oil
pipe connection to camshaft and cylinder heads. If the oil volume is too small for
proper flushing, block some of the jacks and carry out flushing in sequences.
· Rise the main bearing hydraulic jacks and flush the crankshaft. Block some of the oil
holes in crankshaft to ensure proper flushing and carry out flushing in sequences.
· Remove blinds from the oil pipes to camshaft and cylinder heads. Circulate oil
minimum 2 hours and rotate engine after every 15 min.
· Use an additional screen/mesh in the system while flushing. Check the screen and
the oil filter on regular bases to control process. Flushing have to be performed until
mesh and filter stays clean and no further evidence of contamination exist.

7 Start-up
See the engine instruction manual, chapter 03: supervising operation after overhaul,
checking the engine before starting after an overhaul and running-in procedure.

8 Verification
In addition to the running in procedure, it is recommended that following procedure is
followed to verify the condition of the reconditioned pin or journal:
· Running the engine for 3 minutes.
· Complete crankcase inspection, check on bearing temperatures and free movement
of bearing.
· Running the engine for maximum 5 minutes.
· Complete crankcase inspection, check on bearing temperatures and free movement
of bearing.
· Start of normal running in process

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information contained herein. Information in this publication is subject to change without notice.
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due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto. Any actions
by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such actions will
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