Diesel After-Sales Service

Service Bulletin S–1

Technical Information to all the Owners 18.02.94
of Sulzer S 20 Type Diesel Engines

Undersized Bearings and

Reconditioning of
Crankshaft

Contents: Page

– INTRODUCTION 1

– 1. BEARING UNDERSIZES 1

– 2. THRUST RING OVERSIZES 1

– 3. ASSESSMENT CRITERIA 1
FOR CRANKSHAFT

– 4. RECONDITIONING OF 2
CRANKSHAFT

– 5. CLEANLINESS OF 3
CRANKCASE
28.36.07.40 – Printed in Switzerland

– 6. GEOMETRICAL TOLERAN- 4
CES FOR CRANKSHAFT

New Sulzer Diesel Ltd Diesel After-Sales Service PO Box 414 CH-8401 Winterthur, Switzerland
Phone: (052) 262 80 10 (24hours) Telex: 896 659 NSDL CH Telefax: (052) 213 94 83
INTRODUCTION

The purpose of this Service Bulletin is to specify the standard undersizes for the main and
bottom end bearings as well as the oversizes for the thrust rings.
Furthermore, the assessment criteria for the crankshaft journals and pins and their
reconditioning are laid down.

This Service Bulletin should be kept in a separate file in the control room. The respective pages or
tables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manual
or Code Book should be copied and filed in the respective Manual or Book.

1. BEARING UNDERSIZES

On occasions where crankpins or crankshaft journals have to be ground to a smaller

diameter, thicker bearing shells, socalled undersized bearing shells are to be used.
The following undersizes are applicable for main and bottom end bearings (referring to the
diameter).

0.4 - 1.0 - 2.0 - 3.0 - 5.0 - 7.0* mm (For crankpin and jour-
nal Ø d please refer to
enclosure S-1 / 1)

* Recalculation for torsional vibrations may be required. Please contact the engine
builder for advice if journal or crankpin Ø d must be reduced to 7.0 mm undersize.

2. THRUST RING OVERSIZES

Should one of the shoulders of the locating bearing journal become rough, then both
shoulders must be ground back and polished by the same amount, i.e. the total increase of
the distance must be distributed by equal amounts to both sides.
This is of major importance, so that two new thrust rings of the same thickness can be used
to avoid any mixup and to ensure that the crankshaft again runs in its previous correct
position.
The following oversize thrust ring pairs are available:

0.4 - 2.0 - 4.0 mm

For the correct running clearances of the thrust bearing, please refer to the respective page
of the instruction manual.

3. ASSESSMENT CRITERIA FOR CRANKSHAFT

As a consequence of operation under unfavourable conditions, for example with

contaminated lubricating oil, wear of crankpins and/or journals can occur.
Should one of the following wear limits be reached, remachining to the next standard
undersize of the respective pin or journal is recommended.

1/4 Service Bulletin S–1

3.1. Wear Limits

The following figures are applicable to S 20 type engines and refer to diameter:

Wear Journal (mm) Crank Pin (mm)

Circularity max. 0.050 0.080

Cylindricity max. 0.025 0.030

Parallelism max. 0.030 0.030

Circular Runout max. 0.030 0.030

Diameter max. 0.100 0.150

3.2. Measuring Points

= =

1 2 3 4 5 6 7 Micrometer 3

5
6

If all measurements are within the recommended limits but there is still doubt about the
actual general state of the surface, checking with marking blue should be carried out as
described in paragraph 4.3.

4. RECONDITIONING OF CRANKSHAFT

4.1. Polishing of Journals and Crankpins

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

2/4 Service Bulletin S–1

4.2. Remachining of Journals and Crankpins
Remachining of an individual journal or crankpin should be carried out according to enclosure
S-1 / 1.

Diameter Tolerances: Machining tolerances of +0/-0.025 mm are to be applied

for journals and crankpins of S-type engines.

4.3. Blueing of Journals and Crankpins

Following the remachining, a blueing check has to be carried out on the remachined
surface.
Blueing Shell Dimensions
Min. width of the shell must be such, that it covers the whole width of the journal or
crankpin.
Min. circumferential length of the shell must be such, that it covers 1/5 of journal or
crankpin circumference.
Required Bearing Surface Area
Min. 35% equally distributed over width and circumference of journal or crankpin. Please
refer to enclosure S-1 / 2

4.4. Hard Spots on Surface

Even after remachining, a journal or a crankpin may have local hard spots left over as a
result of the bearing failure.
Such local hard surface spots (maximum Ø 30mm) can be tolerated up to a hardness of
500 HV
49 HRc and as long as they are not found around or at the recesses and the bores
for lubrication (please refer to enclosure S-1 / 2).
Furthermore, a journal or a crankpin has to be free of any cracks after remachining,
including any local hard spots.
Crack detection of the journal or crankpin is absolutely essential. Additionally, in case of
doubt, the hard spots should be more closely examined by means of replicas to verify that
they are free of hairline cracks and that their microstructure is still intact as well as free of
Martensite caused by friction.
As a consequence of the local hard spots, the wear of a journal or a crankpin might become
uneven later on in service.

5. CLEANLINESS OF CRANKCASE

Please note:
If remachining of crankpins or journals has to be carried out, especially if any machining or
grinding has to be done in situ, u t m o s t c a r e must be taken to protect the crankshaft, i.e.
to prevent machining and grinding dust from entering into lubricating bores, threaded
holes, crevices etc.
Particular care has to be taken also in covering a l l the oil drains from the crankcase into
the oil sump to prevent any machining or grinding residues from entering the engine's
lubricating oil system through the sump tank.
After finishing such jobs, utmost care must be taken that a l l machining or grinding
residues are removed from the crankcase!

3/4 Service Bulletin S–1

The present instructions were prepared with the utmost care and by taking into
account the situation existing at the time of issue. The instructions may be subject to
later modifications due to further developments, experience or other reasons.
However, neither New Sulzer Diesel Ltd. nor their employees assume any liability for
any claims which may be made on negligence or on any other legal grounds whatever
and which would refer to the contents of these instructions or otherwise be in
connection with them. In particular, but without limiting the generality of the
abovesaid, no liability is assumed regarding any work carried out by any repairer.
On demand of the owner for approval by the relevant classification society, the
repairer submits the parts to be repaired to the local surveyor and informs him about
the work to be carried out. After repairing to the satisfaction of the local surveyor, the
parts are stamped "reconditioned".

6. GEOMETRICAL TOLERANCES FOR CRANKSHAFT

Symbols and Examples of indication and interpretation

toleranced
characteristics Indication on the drawing Tolerance zone Interpretation

0,1 The circumference of each

t crosssection shall be con
Circularity tained between two copla
nar concentric circles 0.1
apart.

0,1 t The considered surface

shall be contained bet
Cylindricity ween two coaxial cylin
ders 0.1 apart.

ÎÎ
ÎÎ
∅ 0,02 A
Parallelism The toleranced axis shall

ÎÎ
be contained in a cylindri
Øt

of a line (axis) with A cal zone of diameter 0.02,

ÎÎ
reference to a dat parallel to the datum axis
um line A (datum line).

0,1 A-B The radial runout shall not

Circular be greater than 0.1 in any
t

Runout plane of measurement du

radial ring one revolution about
A B the datum axis A - B.

New Sulzer Diesel Switzerland Ltd has issued this Service Bulletin with their best knowledge and
ability. However, New Sulzer Diesel Switzerland Ltd can not take any liability for any or all
information contained in this or any other Service Bulletin.
Changes of any nature to the form and or to the content of this or any other Service Bulletin as
published by New Sulzer Diesel Switzerland Ltd, are not permitted.

ENCLOSURES: as mentioned in the text

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 A A B

C
A
C

A 2:1 B 1:1

When refinishing the journal Ø d, the radii have to

be accommodated in such a way that a radial
undercut of 0.5 mm is developed with reference to
the running surface of the journal.

CC 1:1
(for all lubricating oil holes Ø 14 mm)
UNDERSIZE (mm) 0.4 1.0 2.0 3.0 5.0 7.0

UNDERSIZE Ø d
CRANKPINS and 169.6 169.0 168.0 167.0 165.0 163.0*
JOURNALS

DIAMETRICAL TOLERANCES FOR ALL UNDERSIZED 0

CRANKPINS AND JOURNALS -0.025
Transitional zone * Recalculation of torsional vibrations may be required.
N6 N8
from to Please contact the engine builder beforehand.

Service Bulletin Enclosure S–1/1

 Adequate contact pattern,
pronounced chatter marks,
pin must be remachined!

Chatter marks

Good surface appearance

around the lubricating hole.

Note the transition from the

lubricating hole to the run
ning surface. This contact
pattern is unacceptable and
the transition area must be
remachined!

Service Bulletin Enclosure S–1/2