MaintenanceandRepairs

RenewingACrankshaftonaWartsila32
Bearingfailurewillleadtocrankshaftreplacementifoverheatinghastakenplace

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Replacing a crankshaft on a medium speed engine can become necessary after a bearing failure if damage to the
crankshaftjournalshasoccurred,andregrindingofthecrankshaftisnotfeasible.Onolderenginesa0.4%carbonsteel
(EN8orBS970080M40)wasusedforthe manufacture of crankshafts. This material could withstand overheating, and
oftencouldbereground.
Modern crankshafts for medium speed engines are manufactured from high tensile steel for instance a 3% chromium
molybdenum nitriding steel (EN40B or BS 970 722M24). Whether these shafts are surface hardened or otherwise, the
severeoverheatingthatcanoccur(above700C)whenabearingfailsmayrenderthecrankshaftbeyondrepair.Onanone
hardenedcrankshaft,bendingandcrackingcanoccur,togetherwithlocalisedhardening.Wherethecrankshafthasbeen
surfacehardened,thenannealingcanoccur,togetherwithcracking.
The following photographs were taken during a crankshaft replacement on a Wartsila 32 engine. Thanks to John
Koufopoulosforthephotos.

BearingFailure

Inthecasewhereanunderslungcrankshafthastobereplaced,thefollowinggivesaguidetotheprocedure.

The engine is isolated and drained down. Oil is pumped

out. Turbocharger(s) and air cooler removed. Cylinder
heads, pistons and con rods, cylinder liners removed.
Timing gears and camshaft removed (to lighten engine),
Outputshaftdisconnectedandflywheelremoved.

Camshaftremoved
The crankshaft is supported with strops passing up
through the liner bores. Bearing caps are removed, and
the crankshaft can then be lowered. Alternatively the
crankshaftcanbeloweredaftertheframehasbeenlifted
andsupported.
Holding down bolts are removed. The equipment to lift
the engine frame may have to be fabricated and load
tested.Inthecaseshownit takes the form of two plates
withweldedliftingeyesboltedontotheentablatureusing
thecylinderheadstuds.

The engine frame is now lifted to a height which will

allow the crankshaft to be removed either longitudinally
orsidewaysfromtheengine.Theengineframeislanded
onsupports.
In this particular case the crankshaft was removed
longitudinally.

This view is taken lengthways through the engine. Note

the protection wrapped around the bearing cap stud
threadsandthebearingcapslyinginthesumppan.

This view shows the crankshaft prior to fitting in the

engine. Note the projecting studs for fitting the
counterweights.

AboveandBelow:Thenewcrankshaftisbeingliftedandpulledintoposition.NotetheWoodenblocks(below)
supportingtheframe.

Oncethecrankshafthasbeenliftedintopositionandsecuredwithbearingcapstheengineframecanbeloweredbackinto
position, and the holding down bolts replaced. reassembly is basically the reverse of disassembly, with checks for
crankshaft alignment. Rechocking may be required if the alignment has been disturbed, with the engine originally
mountedonresinchocks.
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