Service Bulletin A–16

14.11.97
Technical Information to all the Owners
of Sulzer A/AS/AT25 Type Diesel Engines

Connecting Rod Types

Guidelines for Assessment
at Bottom End

Contents: Page

– INTRODUCTION 1

– 1. DIFFERENT TYPES OF 1
CONNECTING RODS
AND BEARINGS

– 2. CRITERIA FOR RE-USING 2

OR REPLACING
CONNECTING RODS

– 3. GUIDELINES FOR 3
REPLACEMENT OF
CONNECTING RODS
28.38.71.40 – Printed in Switzerland

Wärtsilä NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22

Wärtsilä NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17
Wärtsilä NSD Suisse SA Switzerland Tlx 896 659 NSDL CH
 INTRODUCTION
This Service Bulletin deals with the different types of connecting rods and bearings, the problem of
fretting and adequate countermeasures in order to minimize the risk of incidents originating on
running gear components.

1. DIFFERENT TYPES OF CONNECTING RODS AND BEARINGS

Type 1 and 2 Type 3 Type 4

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Type 1 : 84 Type 1 : 91
Type 2.1 : 84 Type 2 : 84
Type 2.2 : 76

Type A Type B Type C Type D

84 78 78

Type A1 : 90
Type A2 : 78

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1.1 Connecting rods
Type 1 : Superseded
Type 2 : Only applicable for AL / AV 25 engines at 720 / 750 rpm
Type 3 : Introduced for AS 25 engines, previously also used for replacement for A 25 types.
Shot peening of the bore for the bottom end bearing has been introduced later on.
Type 4 : Introduced for AT 25 engines, and suitable for all A and AS 25 types and therefore
preferred standard for replacement. On type 4, the bore for the bottom end bearing
has been shot peened from the beginning.
1.2 Bearings
Type A1 : Superseded
Type A2 : Superseded
Type B : Present standard for connecting rod type 2 (and any type 1)
Type C : Present standard for connecting rod type 3
Warning: Not to be used for connecting rod types 1 or 2
Type D : Present standard for connecting rod type 4 (thin shell type)

2. CRITERIA FOR RE-USING OR REPLACING CONNECTING RODS

2.1 General
It has been observed that in some cases fretting can occur in some areas of the bore and on the
serration. It should be remembered that relative movement and thus signs of fretting in a running
component can never be completely eliminated. This relative movement depends upon specific
surface pressure which in turn depends on the careful and correct tightening of the bolts and studs in
question.
- However, connecting rods must be checked at every overhaul for fretting corrosion and cracks
in the fretting zones.
- The serration between the connecting rod and the bearing cover as well as the whole bearing
bore have to be carefully checked by means of the magnetic particle crack detection method
(Magnaflux) for possible cracks.
- If fretting is visible on small areas, local built-up material can be removed by means of an
oilstone. Warning: Grinding away of large areas of fretting (destruction of the mating
surface shape) and / or scraping away of fretting (creation of notches) are strictly forbidden.
- Remachining of the serration or the bore is not allowed.
- Only minute fretting appearance on a crack-free mating surface can be tolerated.
- Areas treated with an oilstone are to be checked again by Magnaflux.
- Connecting rods which exhibit cracks and/or severe fretting must be scrapped.
- Bearing shells which show signs of fretting on the shell back have to be scrapped.

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2.2 Additional Criteria for Types 1 and 2
In addition to the mentioned items, the following instructions apply for mechanically tightened
connecting rods (type 1 and 2):
- The bush (1) on the upper bolt of the bearing cover has to be removed. Its landing surface (2) as
well as the radius (3) are to be checked for any signs of corrosion. If corrosion is visible, a crack
test (dye-check) has to be carried out.

1
2

- The bolts have to be checked for possible cracks.

- The maximum admissible length of the bolts amounts to 209 mm. Longer ones have to be
replaced.
Important: Bolts and connecting rods exhibiting signs of cracks have to be exchanged
immediately.

3. GUIDELINES FOR REPLACEMENT OF CONNECTING RODS

When connecting rods on an A-type engine are replaced, the following guidelines have to be
adhered to:
- Only one type of connecting rod must be used in an engine.
- If on the same engine several mechanically tightened connecting rods are replaced, we strongly
recommend to exchange all connecting rods with type 4 (hydraulically tightened). A set of
corresponding hydraulically operated tools must be included with the order.
- If an engine is converted from mechanically tightened connecting rods (type 1 or 2) to
hydraulically tightened type 4 (or 3), the crankpins have to be checked for uneven wear due to a
different design of the lubricating groove on the bearings of type A and B compared to bearings
of type C and D. In any case such crankpins have to be equalized or, if necessary, remachined to
the next standard undersize (see our Service Bulletin A-6 ”Undersized Bearings and
Reconditioning of Crankshafts”).
- Connecting rods must only be fitted with the corresponding bearing type.
- A connecting rod is machined together with its bearing cover. They are marked accordingly.
These two parts form a unit and must never be interchanged with parts from other connecting
rod assemblies.
- The instructions to fit the bearing shells and to tighten the connecting rods have to be strictly
observed.

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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.
Wärtsilä NSD Switzerland Ltd has issued this Service Bulletin with their best knowledge and
ability. However, Wärtsilä NSD 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 Wärtsilä NSD Switzerland Ltd, are not permitted.

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