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Service Bulletin A-6.2: 18.12.98 Technical Information To All Owners / Operators of Sulzer A20 and A/AS/AT25 Engines
Service Bulletin A-6.2: 18.12.98 Technical Information To All Owners / Operators of Sulzer A20 and A/AS/AT25 Engines
A6.2
18.12.98
(Supersedes Bulletin
A6.1 of 27.02.98)
Contents:
Page
4. Assessment Criteria
for Crankshaft
5. Reconditioning
6. Flushing
PO Box 414
CH-8401 Winterthur
Switzerland
2. Bearing Undersizes
1. Introduction
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
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
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.
1/3
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
2/3
5.1.
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.
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
AL20
N5
Change from N6 to N8
C-C
(smooth transitions)
D-D
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
AL/ASL/ATL25
N5
C-C
Change from
N6
to
N8
(smooth transitions)
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
AV/ASV/ATV25
N5
C-C
Change from
N6
to
N8
(smooth transitions)
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
Chatter marks
GEOMETRICAL TOLERANCES
Symbols and
toleranced
characteristics
Tolerance zone
0.1
Circularity
0.1
0.02 A
0.1 A-B
Circular
Runout
radial
Cylindricity
Parallelism
of a line (axis)
with reference to
a datum line
Interpretation