Caterpillar G3616 Crankshaft

The Caterpillar G3616 gas engine met with an accident and, upon preliminary inspection, was found to be damaged.

RA Power Solutions’ technicians arrived at the site near Tehran and inspected the crankshaft of the Caterpillar G3616. The following are the main observations:

(i) The crankpin bearing of Number #03 was severely stuck to the crankpin surface. The top layer of the bearing had melted and become embedded in the crankpin diameter.

(ii) The bearing material embedded in the crankpin surface was removed to facilitate inspection for hardness, presence of cracks, and dimensional accuracy.

(iii) The minimum and maximum crankpin diameters observed are as follows:

(a) Minimum diameter: 214.93 mm

(b) Maximum diameter: 216.00 mm

Against the standard diameter of 216.00 mm, an ovality of 1.07 mm was observed

(iv) Minor surface cracks were also observed during the MPI (Magnetic Particle Inspection).

(v) Hardness was found to be within acceptable limits, except at a few spots.

Saving of Caterpillar G3616 Crankshaft From Rejection

Based on the fact that the ovality in crankpin number #03 was observed to be 1.07 mm, an inquiry was sent to the manufacturer. The manufacturer informed us that the maximum allowable undersize for the crankpin is 1.00 mm, meaning the minimum acceptable diameter must be 215.00 mm. In this case, since the damage had already reached 1.07 mm, the crankshaft is considered rejected, as per the manufacturer’s guidelines. In this case, the expected undersize after grinding was 2.00 mm, which is beyond the permissible limit.

RA Power Solutions has undertaken onsite grinding of Crankpin Number #03, reducing its size by 2.00 mm, and the following dimensions were maintained after grinding:

a) Minimum diameter observed: 213.98 mm

b) Maximum diameter observed: 214.00 mm

RA Power Solutions, a company providing services for the past 45 years, arranged a 2.00 mm undersized bearing for the Caterpillar G3616 crankshaft through a leading manufacturer based in Germany.

The engine has been assembled and is performing satisfactorily.

We have been regularly executing the on site crankshaft repairs and crankshaft grinding of different engines, like Caterpillar, Wartsila, Cummins, Yanmar, Daihatsu and MAN and MAK in Iran, Iraq, 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 information regarding crankshaft grinding services, please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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Crack Detection Test of Wartsila VASA Engine Model 12V32LN By MPI	Hardness Test of Wartsila VASA Engine Model 12V32LN

Main observations of the crankshaft of Wartsila Vasa are :

(I) On a visual inspection of crankpin number one, having a standard diameter of 270 mm, it was found to be damaged with deep line marks, pitting, and a rough surface.

(II) The crankpin was subjected to dimensional inspection after cleaning the embedded bearing material. The following measurements were observed for Crankpin Number One:

Minimum Diameter: 269.45 mm

Maximum Diameter: 269.89 mm

Ovality Observed: 0.55 mm

(III) All other crankpins were visually inspected, and no damage or marks were observed.

(IV) As per standard procedure, Crankpin Number One was subjected to a crack detection test using the MPI process, and hardness testing was also carried out. No abnormalities were observed

(V) Crankpin Number One was undersized by on site crankshaft grinding equipment. The diameter was reduced by 1 mm to control ovality and to remove the line marks observed after the bearing seizure. The final crankpin diameter was maintained as 269.00 – 0.02 mm.

Assembly of Crankshaft Grinding Machine on Damaged Crankpin	Onsite Grinding Under Process

RA Power Solutions, during its long-standing presence in the industry, has executed repair of over 1300 Wartsila engine crankshafts of various models. The most popular models serviced include WARTSILA 12V32 and WARTSILA 18V32, widely installed in diesel power plants around the world.

At RA Power Solutions, we specialize in on site crankshaft grinding for Wartsila, Yanmar, MAN, and MAK engines, offering a reliable and cost-effective solution to repair damaged or worn crankshafts without removing them from the engine.

This advanced service not only eliminates the need for engine disassembly and costly transportation but also significantly reduces downtime. Using state-of-the-art portable grinding equipment, our expert technicians restore the crankshaft’s dimensions and surface finish to OEM standards, ensuring optimum engine performance.

Wartsila VASA Engine Model 12V32LN Grinding Under Process	Crankpin Inspection Under Progress Before Polishing

With over four decades of experience, we’ve successfully delivered onsite crankshaft grinding services across the globe—including Burkina Faso, Bangladesh, Dubai, Indonesia, Singapore, and many other ports and shipyards worldwide. No matter where your vessel or power plant is located, RA Power Solutions is ready to respond with precision, speed, and expertise.

Get in touch with us today for expert services in onsite crankshaft repair, crankpin polishing, crankshaft reconditioning, and in-situ crankshaft grinding. Our team is equipped to provide fast and reliable solutions, wherever your engine is located. For inquiries or service requests, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 / +91 9810012383. We’re here to support you—anytime, anywhere.

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Action taken by RA Power Solutions to repair the crankshaft of MAK 8CM32C :

RA Power Solutions deputed two technicians with an onsite crankshaft grinding machine, instruments, and necessary consumables.

Upon arrival, they inspected the crankshaft of a damaged diesel generating set of MAK 8CM32C.

The details of the job are as follows:

The dimensional inspection of the damaged and seized crankpin number #7 was conducted.

• Dimensional checks revealed:

Minimum Diameter: 279.68 mm

Maximum Diameter: 280.00 mm

Ovality: 0.32 mm

Apart from an ovality of 0.32 mm, the crankpin exhibited deep scoring marks and a rough surface, which was developed due to seizure of the bearing.

• The hardness was checked and showed marginally higher values in certain spots.
• MPI for crack detection was undertaken and revealed no cracks or abnormalities.
• The remaining crankpins were also inspected for taper and ovality and all within acceptable limits.

Action taken for the successful repair of the crankshaft of MAK 8CM32C :

i) The grinding of crankpin number #7 was ground to an undersize of 3 mm; this was done as the deep line marks were present at every step.
They got cleared only after grinding the crankpin to 3 mm undersize, resulting in a final diameter of 277.00 mm.

ii) The remaining crankpins were polished to improve surface finish and reduce the ovality by 0.01/0.02 mm.

The above job of crankshaft repair of MAK 8CM32C has been executed strictly as per the requirements of the manufacturers and the tolerance specified.

Successful Worldwide Onsite Crankshaft Repairs

RA Power Solutions has successfully executed onsite crankshaft grinding and repair of MAK, MAN, Daihatsu, and Yanmar engines in over 100+ countries worldwide. Our services are trusted across India, UAE, Singapore, Colombia, Indonesia, Malaysia, Bangladesh, Saudi Arabia, Qatar, Kenya, Nigeria, Greece, Turkey, Spain, the UK, USA, Brazil, and many more.

For expert onsite crankshaft grinding of MAK 8CM32C engine repair and other crankshaft repair services, contact RA Power Solutions today.

Our team is available 24/7 to provide prompt support worldwide, ensuring high-quality, reliable, and cost-effective solutions.

Call us at +91-9582647131 or email info@rapowersolutions.com.

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We recently completed a successful onsite repair of a BERGEN B32:40L8P engine crankshaft onboard a vessel in Jamaica.

The details of the job are as follows:

Onsite Inspection of Crankshaft – BERGEN B32:40L8P

• Two of our experienced technicians, along with our portable onsite crankshaft grinding equipment, traveled from New Delhi, India, to Jamaica.
• Our equipment is lightweight, compact, and portable, allowing it to be transported as accompanied baggage, which eliminates delays associated with cargo shipment and customs clearance.
• Upon boarding, the vessel was found fully loaded with containers, yet our team immediately initiated the crankshaft inspection.
• It was observed that Crankpin No. 5 had suffered severe damage due to a bearing failure.
• The crankpin was thoroughly cleaned, and embedded bearing material was carefully removed.
• Dimensional checks revealed:
  • Minimum Diameter: 269.75 mm
  • Maximum Diameter: 270.00 mm
  • Ovality: 0.25 mm
  • Deep scoring marks were also noted due to the bearing failure.
• A Magnetic Particle Inspection (MPI) using a high-intensity Magnaflux torch was conducted to check for cracks. No cracks or abnormalities were detected.
• Hardness testing was performed, and confirmed that values remained within permissible limits.

Onsite Grinding of BERGEN Crankpin

• The crankpin was calibrated and ground in multiple stages, with ovality strictly controlled during the process.
• Due to deep scoring, the crankpin had to be ground to an undersize of 2 mm.
• The final dimension achieved was 268.00 mm – 0.02 mm, ensuring precision and compliance with engine requirements.

Engine Commissioning

• The vessel had a 2 mm undersize bearing in stock, which was installed immediately after grinding.
• A trial run of the engine was conducted in the presence of our technicians, and performance was found to be fully satisfactory.

About RA Power Solutions

We are a global leader in onsite crankshaft grinding and repair services for crankpins and main journals up to 700 mm. With over four decades of hands-on experience, we are Asia’s most established and trusted company in this field.

We are the original developers and manufacturers of portable onsite crankshaft grinding machines. Our machine design originates from a reputed Italian engineering firm. To date, we have supplied over 80 onsite crankshaft grinding machines across the globe.

In addition to repair services, we also supply the complete range of tools and measuring instruments necessary for crankshaft repairs.

We offer hands-on training programs for client technicians at our in-house training center in New Delhi, India, conducted by our expert engineers. Our training sessions have been successfully delivered to clients from Colombia, Panama, Ecuador, Dubai, Singapore, Bangladesh, Tanzania, and many other countries.

For more information regarding crankshaft grinding services, Crankshaft Repair, please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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Action Taken By RA Power Solutions For Repair of Crankshaft Yanmar 8N 330L EV

i) Since the vessel was anchored near Panama Port, RA Power Solutions deputed two technicians having a valid US VISA and Seaman book. Both technicians flew to Panama along with onsite crankshaft grinding machine and measuring instruments and boarded the vessel within 48 hours of the client’s first information of the breakdown of crankshaft of Yanmar 8N 330L EV.

The Details of Engine / Crankpin are as following:

ii) RA Power Solutions technicians inspected all the crankpins (8 Nos) to check the taper & ovality, the dimensions of observed are pasted below.

iii) On going through the readings, it was observed that the crankpin number #02 has developed excessive ovality of 0.43 MM, against the tolerance of 260.00 MM + 0.03 MM. This is considered very much on the higher side. All other crankpins also have ovality ranging from 0.09 MM to 0.10 MM, The bearing line marks and rough surface on the crankpin were observed.

iv) As a Protocol, hardness was checked of eight (8 Nos) Crankpins and was observed within limits.

v) Crack detection was also conducted, and no crack was observed on damaged crankpin number #02 and other crankpins.

vi) It was jointly decided to undertake the grinding of crankpin number #02 and polishing the remaining crankpins to remove the bearing line marks and to improve the surface finish.

vii) Although in the crankpin numbers #01,#03,#04,#05,#06,#07, and #08 the ovality was observed on the higher side as 0.10 MM, however, this was accepted under divation.

viii) The Crankpin number #02 was undersized by 1.5 MM, A Final Dimensional Report after grinding and polishing of crankpins of Yanmar 8N 330L EV is pasted below.

ix) In order to assist ship staff, our technicians undertook the dimensional and MPI Inspection of connecting rods available on the vessel, they were observed within limits.

The engine was commissioned during the presence of our technicians on the vessel.

We have been regularly executing on site crankshaft repairs and In Situ crankshaft grinding in Dubai, Fujairah, Qatar, Saudi Arabia, Oman, Iraq, Togo, Malta, Freetown, Egypt, Malaysia, Iran, Indonesia, Vietnam, Jordan, etc.

We have a team of trained technicians available 24/7 hrs and can be deputed on short notice. Some of our technicians also have valid US VISA and can fly to South America, Caribbean countries, etc.

For more information regarding crankshaft grinding services, please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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We have trained, qualified, and experienced technicians to undertake crankshaft inspection & to execute the crankshaft repair successfully after Pre-inspection is conducted.

Following services for crankshaft inspection on site & crankshaft repair are offered

• Inspection services for damaged crankshaft onsite or on board a vessel.
• In case of damaged crankshaft, we depute our experienced technicians to undertake inspections all over the world for land-based Diesel engines or main & auxiliary engines installed on the vessel.
• Technicians travel to the site in the minimum possible time as all our technicians have the necessary certificates & CDC which facilitates them to fly to any destination all over the world.
• Technicians carry with them calibrated latest breed of instruments to conduct the crankshaft inspection and crankshaft repair on site.

The crankshaft inspection includes the following

• Visual inspection of radius fillet, lubricating oil hole, counterweight, and complete crankshaft for any damage.
• Dimensional inspection of crankpin and main journal (in case possible) to check taper & ovality.
• Hardness test.
• Crack detection by MPI with the latest model of high-intensity magnaflux torch.
• In certain cases, a dye penetrant test is also undertaken.
• Surface roughness test by the latest model of the Mitutoyo surface testing instrument.
• Computerized reports are prepared in RA Power technical format and are submitted to the client.
• In case required RA Power Solutions can immediately depute a team of technicians with an onsite crankshaft/ cylindrical shaft grinding machine to execute the repair as per the International standards & specifications.

Inspection of the Crankshaft of the MAN Engine for purchase/ Replacement

The shipbreaking yard of Alang based in western India is coming up as the largest shipbreaking yard in the world. We offer crankshaft inspection services in case any of our clients want to purchase a used crankshaft or any major components like the engine block, connecting rod, cylinder head, turbocharger, etc. We also have the facility to undertake in-house reconditioning of the major parts removed from the engine.

Inspection of the crankshaft of the MAN Engine during routine maintenance

We strongly recommend inspection of the crankshaft during the routine maintenance of marine engines, and engines in operation in industries. The cost of on site inspection is negligible in comparison to the cost of a new crankshaft which needs replacement in case of damage. During the maintenance period, our technicians visit the installation and inspect the crankshaft in detail. We have the latest design of portable polishing & grinding machines available up to 700 mm diameter so that timely necessary corrective action can be undertaken.

We also conduct on site inspections of the following parts

• Turbine shaft
• Alternator shaft
• Rotor shaft
• Pump shaft
• Gear Box shaft

We have been regularly executing the inspection and 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, Saudi Arabia, Iraq, UAE, etc.

For more information about crankshaft inspection on site, inspection of Crankshaft of MAN Engine, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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