A COMPLETE ENGINE REPAIR JOURNAL GRINDING, ANNEALING, LASER ALIGNMENT, LINE BORING AND ENGINE REBUILD

PROJECT FACTS: SWD 8SW280
Original Crankpin Diameter: 220.00 mm
Finished Crank pin Diameter: 217.00 mm
Main Journal Diameter: 220.00 mm
Finished Main Journal Diameter: 218.00 mm
Pre-Annealing Hardness (Max): 600 Brinell
Post Annealing Hardness (Max): 375 Brinell

A COMPLETE ENGINE REPAIR
JOURNAL GRINDING, ANNEALING, LASER
ALIGNMENT, LINE BORING AND ENGINE
REBUILD
Goltens was presented with a challenging opportunity in
Honduras. The customer’s engine had incurred significant
damage to the crankshaft and block. Goltens’ technicians
performed an evaluation of the shaft and engine and found
that the crankshaft was damaged on one Main journal and
one Crankpin journal and hardness tests showed areas in
both journals around 600 Brinell. In order to save the shaft, it
would need to be annealed. Additionally, the main journal
pocket was damaged by the main journal bearing failure and
had to be line bored and so the crankshaft was removed
from the engine.
Do to the remote location of the plant, the customer did not
want to incur the costs of shipping the shaft overseas to be
reconditioned in the workshop and requested that Goltens
perform all repairs on site.
Goltens mobilized Diesel technicians and tools to
disassemble the engine and remove the crankshaft.
Simultaneously Goltens mobilized in-situ line boring,
crankshaft grinding, annealing equipment and technicians to
site. Goltens grinded all journal surface cracks out prior to
annealing the crankshaft which reduced hardness to
acceptable levels below 375 Brinell. While the shaft was
being annealed, the crankcase and frame were mounted
back again and a laser alignment and line boring was
completed with all main bearing cap landing surfaces
machined in order to keep the original main journal bore
diameter.
After the line boring the shaft was placed back in the engine
again. Engine was built up again and test run performed by
Goltens technicians.

REPAIRS CONSISTED OF:
• Diameter measurement, Magnaflux and Hardness testing
of crankshaft
• Grinding of Main and Crankpin journal until free of cracks
• Disassembly of engine and removal of crankshaft
• Annealing of both journals to remove excessive hardness
• Laser bore alignment check of all main journal bores
• Machining all lower bearing caps
• Line Boring of all main bearing pockets to standard size
• Reinstallation of crankshaft and reassembly of the
engine block
• Finish grinding of the crankshaft to 2.00mm and 3.00mm
undersize for main and crankpin journals respectively
• Reassembly of all engine components, completion of
pre-start checks and operational run in of the engine
RESULTS:
Goltens technicians completed the entire engine repair onsite
using its full capabilities as specialist engine repair
engineers and In-Situ machining specialists. The engine was
restored to full operation and the customer avoided the cost
of transporting the damaged components to a remote
workshop for repair.