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Service Bulletin

A6.2

Technical Information to all Owners / Operators


of Sulzer A20 and A/AS/AT25 Engines

18.12.98
(Supersedes Bulletin
A6.1 of 27.02.98)

Undersized Bearings and


Reconditioning of Crankshafts

Contents:

Page

4. Assessment Criteria
for Crankshaft

5. Reconditioning

6. Flushing

PO Box 414
CH-8401 Winterthur
Switzerland

3. Thrust Ring Oversizes

Wrtsil NSD Switzerland Ltd


Wrtsil NSD Schweiz AG
Wrtsil NSD Suisse SA

2. Bearing Undersizes

28.02.07.40 Printed in Switzerland

1. Introduction

Tel. +41 52 262 49 22


Fax +41 52 212 49 17
Tlx 896 659 NSDL CH

1.

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.
It also contains the correct assessment criteria for the crankshaft journals and pins as well as their
reconditioning.
The previous edition contained a misprint of the diameters in the table of its enclosure A6.1/4.
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.
2.

BEARING UNDERSIZES

The following undersizes apply (referred to the diameter):


Engine Type

crankpin

journal

A20

A25

AS25

ATL25

Undersizes

0.2
0 21) - 0.4 - 0.8 - 1.2 - 1.71) - 2 3 - 3 0 - 3 71) - 4 5 -7 02)
04 08 12 17
2.3 3.0 3.7
4.5 -7.0

ATL25

ATV25

0.4 1.0 2.0 3.0 5.0 7.0


0 4 1 0 2 0 3 0 5 0 7 02)

1)

Our stock for these undersizes will be used-up and phased-out. Please inquire for availability
prior to grinding to the final diameter.

2)

Re-calculation of torsional vibrations could be required. Please contact the engine builder
beforehand.

3.

THRUST RING OVERSIZES

The following oversizes apply for individual rings:


0.4 0.8 1.2 mm
For collar tolerances after remachining please refer to the respective table in the Maintenance
Manual.
4.

ASSESSMENT CRITERIA FOR CRANKSHAFT

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


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

1/3

Service Bulletin A-6.2

4.1.

Wear Limits

The following deviation limits as a result of wear are applicable to all A-type engines and refer to
diameter.
Journal (mm)

Crankpin (mm)

Circularity

Max.

0.040

0.060

Cylindricity

Max.

0.020

0.025

Circular Run-out

Max.

0.030

0.030

Diameter

Max.

0.080

0.120

For details about the above mentioned geometrical tolerances, please refer to enclosure A-6.2/8.
4.2.

Measuring Points
=

=
1
2

Micrometer
4
6

If all measurements are within the limits but there is still doubt about the actual general state of the
surface, checking with blue should be carried out as described in paragraph 5.1.
5.

RECONDITIONING

Remachining of an individual journal or crankpin should be carried out according to enclosure


A-6.2/1 and 2 for AL20, A-6.2/3 and 4 for AL/ASL/ATL25 or A-6.2/5 and 6 for AV/ASV/ATV25
engines respectively.
A journal or a crankpin with a roughened surface, but with dimensions still within the limits, should
be polished. Polishing should not be carried out by hand with emery or polishing paper.
However, reconditioning of crankshafts should only be carried out by a specialized firm, for this
reason please contact Wrtsil NSD Switzerland Ltd or one of our Network Companies.

2/3

Service Bulletin A-6.2

5.1.

Quality of a remachined Pin or Journal

The quality of a pin or journal after machining has to meet the following requirements:

Geometrical tolerances in accordance with enclosures A-6.2/1 and 2 (AL20), A-6.2/3 and 4
(AL/ASL/ATL25) or A-6.2/5 and 6 (AV/ASV/ATV25) respectively.

A blueing check has to be carried out on the remachined surface. Blueing Shells: Min. width
equivalent to 2/3 of the journal or crankpin dimensions respectively. Min. length equivalent to
1/5 of journal or crankpin circumference.
Required contact area: Min. 35% equally distributed over width and circumference (please
refer to enclosures A-6.2/7 and 8).

Free of hairline cracks: Journal or crankpin to be tested by means of magnetic particle crack
detection method.

Free of martensite: The microstructure is to be tested for white edged areas of martensite
structure with replicas or macro etching with 5% nitric acid in alcohol (Nital) applied to the pin
after polishing.

Maximum admissible hardness of remaining local hardspots: 400HB.


However, such local hardspots are not tolerated around the fillets and the bores for lubrication.

6.

FLUSHING

After remachining, the lubricating oil system has to be flushed according to our Service Bulletin
Flushing Instructions.

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

3/3

Service Bulletin A-6.2

AL20

* With the bearing covers, except the one of the


remachined journal, mounted and tightened correctly.
** On the whole circumference.

for the whole fillet

N5

Change from N6 to N8

C-C

(smooth transitions)

D-D

Service Bulletin Enclosure A6.2/1

AL20
- When remachining a journal and/or crankpin diameter 'D' or 'd', the dimension 'a' of the
fillet (see detail 'A' ), and radii 'R' (see detail 'B') must be adapted in such a way that radial
fillets of 0.2 and 0.5mm in relation to the journal or crankpin surface result again.
- After remachining, the transitions between running surface and lubricating oil holes have
to be rounded off with a radius R=4mm and polished.
- After final machining, journals, crankpins and fillets must be checked for cracks by means
of a magnetic particle crack test (afterwards demagnetizing) or the dye penetrate method.
Undersize (mm)

0.2*

Undersized
Journals 'D'

164.8 164.6 164.2 163.8 163.3 162.7 162.0 161.3 160.5 158.0

Undersized
Crankpins 'd'

154.8 154.6 154.2 153.8 153.3 152.7 152.0 151.3 150.5 148.0

0.4

0.8

1.2

1.7*

2.3

3.0

3.7*

4.5

7.0**

For the undersize crankpin diameters marked by * please contact Wrtsil NSD
Switzerland Ltd, or one of our Network Companies, before start with grinding to one of
these diameters. These undersize diameter bearing shells will be phased out.
For engines in service which have been already equipped with one of these undersize
bearings, these bearings can be used as long as they are available. Otherwise the crankpin
has to be ground to the next smaller diameter.

** Recalculation of torsional vibrations could be required. Please contact the engine builder
beforehand.
0
Note: Diameter tolerances for all undersized journals and crankpins: -0.025

Service Bulletin Enclosure A6.2/2

AL/ASL/ATL25

* With the bearing covers, except the one of the


remachined journal, mounted and tightened correctly.
** On the whole circumference.

for the whole fillet

N5

C-C
Change from

N6

to

N8

(smooth transitions)

Service Bulletin Enclosure A.6.2/3

AL/ASL/ATL25

When remachining a journal and/or crankpin diameter D or d, the dimension a of the fillet (see
detail A ), and radii R (see detail B) must be adapted in such a way that radial fillets of 0.2 and
0.5mm in relation to the journal or crankpin surface result again.

After remachining, the transitions between running surface and lubricating oil holes have to be
rounded off with a radius R=4mm and polished.

After final machining, journals, crankpins and fillets must be checked for cracks by means of a
magnetic particle crack test (afterwards demagnetizing) or the dye penetrate method.

Engine
Type

Undersize
(mm)

AL25
ASL25
ATL25

Undersized
Journals 'D'

0.2*

0.4

0.8

1.2

1.7*

2.3

3.0

3.7*

4.5

7.0**

199.8 199.6 199.2 198.8 198.3 197.7 197.0 196.3 195.5 193.0

AL25
Undersized
194.8 194.6 194.2 193.8 193.3 192.7 192.0 191.3 190.5 188.0
ASL25 Crankpins 'd'

Engine
Type

0.4

1.0

2.0

3.0

5.0

7.0**

ATL25
*

Undersize (mm)
Undersized Crankpins 'd'

194.6

194.0

193.0

192.0

190.0

188.0

For the undersize crankpin diameters marked by * please contact Wrtsil NSD Switzerland Ltd, or
one of our Network Companies, before start with grinding to one of these diameters. These
undersize diameter bearing shells will be phased out.
For engines in service which have been already equipped with one of these undersize bearings, these
bearings can be used as long as they are available. Otherwise the crankpin has to be ground to the
next smaller diameter.

** Re-calculation of torsional vibrations could be required. Please contact the engine builder
beforehand.
0
Note: Diameter tolerances for all undersized journals and crankpins: -0.029

Service Bulletin Enclosure A6.2/4

AV/ASV/ATV25

* With the bearing covers, except the one of the


remachined journal, mounted and tightened correctly.
** On the whole circumference.

for the whole fillet

N5

C-C
Change from

N6

to

N8

(smooth transitions)

Service Bulletin Enclosure A6.2/5

When remachining a journal and/or crankpin diameter D or d, the dimension a of the fillet (see
detail A ), and radii R (see detail B) must be adapted in such a way that radial fillets of 0.2 and
0.5mm in relation to the journal or crankpin surface result again.

After remachining, the transitions between running surface and lubricating oil holes have to be
rounded off with a radius R=4mm and be polished.

After final machining, journals, crankpins and fillets must be checked for cracks by means of a
magnetic particle crack test (afterwards demagnetizing) or the dye penetrate method.

Type
Engine
AV25
ASV25

Engine
Type
ATV25
*

Undersize
(mm)
Undersized
Journals D

0.2*

0.4

0.8

1.2

1.7*

2.3

3.7*

3.0

4.5

7.0**

224.8 224.6 224.2 223.8 223.3 222.7 222.0 221.3 220.5 218.0

Undersized
194.8 194.6 194.2 193.8 193.3 192.7 192.0 191.3 190.5 188.0
Crankpins d

Undersize (mm)

0.4

1.0

2.0

3.0

5.0

7.0**

Undersized Journals D

224.6

224.0

223.0

222.0

220.0

218.0

Undersized Crankpins d

194.6

194.0

193.0

192.0

190.0

188.0

For the undersize crankpin diameters marked by * please contact Wrtsil NSD Switzerland Ltd, or
one of our Network Companies, before start with grinding to one of these diameters. These
undersize diameter bearing shells will be phased out.
For engines in service which have been already equipped with one of these undersize bearings, these
bearings can be used as long as they are available. Otherwise the crankpin has to be ground to the
next smaller diameter.

** Re-calculation of torsional vibrations could be required. Please contact the engine builder
beforehand.
0
Note: Diameter tolerances for all undersized journals and crankpins: -0.029

Service Bulletin Enclosure A6.2/6

CONTACT AREA OF PIN

Adequate contact pattern but


pronounced chatter marks, pin
must be remachined!

Chatter marks

Note the transition from the


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

Service Bulletin Enclosure A6.2/7

Good surface appearance


around the lubricating hole.

GEOMETRICAL TOLERANCES
Symbols and
toleranced
characteristics

Examples of indication and interpretation


Indication on the drawing

Tolerance zone

0.1

Circularity

0.1

0.02 A

The toleranced axis shall be


contained in a cylindrical zo
diameter 0.02, parallel to th
datum axis A (datum line).

0.1 A-B

Circular
Runout
radial

The circumference of each


crosssection shall be conta
between two coplanar
concentric circles 0.1 apart.

The considered surface shall


be contained between two
coaxial cylinders 0.1 apart.

Cylindricity

Parallelism
of a line (axis)
with reference to
a datum line

Interpretation

The radial runout shall not


greater than 0.1 in any plan
measurement during one re
about the datum axis A - B

Service Bulletin Enclosure A6.2/8