Repair of Daihatsu 5DK-20 Crankpin Machining | Daihatsu Crankshaft Repair | RA Power Solutions

A container vessel operating between Indonesia, India and Srilanka met with a serious accident involving one of their auxiliary engine of Daihatsu 5DK-20.

Team of two technicians was deputed who boarded the vessel at Batam port in Indonesia and assessment of the crankshaft was undertaken.

Following are the main observations:-

MAIN OBSERVATIONS OF DAMAGE CRANKSHAFT OF DAIHATSU 5DK-20:-

THE CRANKSHAFT DETAILS ARE AS FOLLOWING:-

* The assessment of crankpin no.5 was undertaken and it was observed that crankpin was damaged to the extent of 0.80 mm against the standard diameter of 170.00 mm, the diameter was reduced after the accident to 169.20 mm.

• The crankpin journal surface was blued and scored because of the heat generated due to crankpin bearing failure.
• The bearing material was also welded up on the crankpin journal surface.
• The bearing material was removed with great difficulty and a crack detection test was undertaken by MPI process using the magna flux torch of high intensity.
• Multiple cracks having the length ranging from 4 mm to 16 mm were observed on the bearing journal surface.
• In case of failure of bearing, it is not only important to check the presence of cracks but reading of hardness is also of great importance.
• The hardness of the crankpin was checked and few scattered hard spots were observed. Nothing alarming was observed
• Considering the serious damage of crankpin no. 5, the necessity of checking alignment of the crankshaft was communicated to the chief engineer.
• The deflection reading of the complete crankshaft was taken and observed within limits.
• Our technicians also removed the adjacent caps of the main journal and checked the run out of the main journal with the help of magnetic dial gauge.
• The alignment of the crankshaft and deflection readings were observed within limits and this was a great relief for our technicians.

ACTION TAKEN FOR MACHINING OF CRANKSHAFT OF  DAIHATSU 5DK-20 ENGINE:-

• After initial inspection as per details mentioned above, the grinding of crank pin was started with a portable, pneumatic onsite crankshaft grinding machine.
• Since the vessel was a container vessel, the grinding of crank pin was undertaken while the sailing of the vessel as no stoppage was permissible as per the sailing schedule.
• The crankpin was finally ground to the size of 167 mm which is 3.0 mm  under size in comparison to standard size of 170 mm of crankpin. The tolerance in terms of taper and ovality was maintained within 0.03 mm
• The surface finish of the crankpin journal and all other parameters were again checked and recorded.
• The engine was assembled and was commissioned.

ACHIEVEMENT OF RA POWER SOLUTIONS TECHNICIANS:-

In the time of covid-19, the technicians boarded the vessel in minimum time as all our technicians carry valid Indian CDC.

The complete inspection of the crank pin which was badly damaged due to serious accident and grinding of crankpin to the undersize of 3.0 mm was executed in a short time of only 69 hours and the engine was put back into operation.

We have been regularly executing the repairs in Argentina, Bahamas, Barbados, Bermuda, Bolivia, Brazil, Canada, Chile, Colombia, Costa Rica, Cuba, Dominican Republic, Ecuador, El Salvador, Guatemala, Guyana, Haiti, Honduras, Jamaica, Mexico, Nicaragua etc.

This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions India Pvt. Ltd.).

Mr. Shahani is a highly experienced business leader with rich experience of more than 40 years in the field of Power, Heavy and Shipping industry. He is Technical Adviser to many shipping and heavy industries across the globe.

Mr. Shahani is one of the most enthusiastic professional and he has all the brilliance of an exemplary leader. Mr. Shahani is an extremely effective coach and mentor of teams and is adept at providing leadership in a global, cross-cultural environment.

For more information, please email us at rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Visit our website:  http://rapowersolutions.com/ or https://crankshaftgrindingmachine.com/

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