Caterpillar G3616 Crankshaft Repair in Tehran, Iran

In Iran, people widely use diesel generator sets to generate electricity. One of our clients runs several diesel generators at various locations throughout Tehran. These generators usually run nonstop for several days at a time, only stopping for planned preventive maintenance.
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 the Caterpillar G3616 Crankshaft From Rejection

Given that crankpin No. 03 had an ovality of 1.07 mm, the manufacturer was contacted for clarification. According to the manufacturer, the crankpin's maximum acceptable undersize is 1.00 mm, which translates to a minimum allowable diameter of 215.00 mm.

According to the manufacturer's instructions, the crankshaft is rejected because the damage in this instance had already surpassed this limit at 1.07 mm. Additionally, it was calculated that the expected undersize following regrinding would be 2.00 mm, which is far larger than the permitted 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 46+ 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 provide crankshaft grinding, in-situ crankshaft grinding, onsite crankpin polishing, damaged engine repair, and worldwide crankpin repair services, covering major industries and engine applications across SAUDI ARABIA, UNITED ARAB EMIRATES, QATAR, KUWAIT, OMAN, BAHRAIN.

For your requirement of crankshaft repair, crankshaft grinding, in-situ crankshaft grinding, onsite crankpin polishing, damaged engine repair, or worldwide crankpin repair services, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

Source URL: https://www.crankshaftgrindingrepair.com/caterpillar-g3616-crankshaft-repair-in-tehran-iran/

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