Caterpillar 3516 Crankshaft Repair Onsite

A Caterpillar 3516 crankshaft met with an accident in a diesel generating set installed in a gold mine in Burkina Faso. In the gold mine, all equipment is operated by power generated through diesel generating sets. The critical operations of the gold mine came to a standstill due to the breakdown of the Caterpillar 3516 diesel generator crankshaft.

RA Power Solutions, having a global presence in the repair of crankshafts of main and auxiliary engines up to 700 mm in diameter for the last 46 years, was approached by the client and was asked to explain the need for immediate repair of the crankshaft. RA Power Solutions dispatched two technicians and onsite crankshaft repair equipment to Burkina Faso.

Damaged Crankpin of Caterpillar 3516 Engine	Close-Up of Damaged Crankpin – Caterpillar 3516

The details of the engine and crankshaft are as follows:

On going through the above details, one can observe that the diameter of the crankpin is very small, i.e., 135.00 mm, and the bearing width is 120.00 mm. RA Power Solutions, with their experience, has designed, developed, and manufactured a compact onsite crankshaft grinding machine, which can be inserted through the inspection window of the engine block.The machine is manufactured in two parts and sits on the crankpin diameter.

Hardness Testing of Caterpillar 3516 Crankshaft	Hardness Test on Crankpin – Caterpillar 3516 Engine

Inspection of the Caterpillar 3516 Crankshaft

On inspection of the oil sump and Caterpillar crankshaft, it was observed that crankpin number 07 was damaged. The following steps were taken:

a) The connecting rod was opened.

b) Crankpin number 07 was subjected to dimensional inspection for taper, and ovality of 0.80 mm was observed.

The minimum and maximum diameters of crankpin number 07 were as follows:

• Minimum diameter: 134.20 mm

• Maximum diameter: 135.00 mm

c) Visual inspection of the damaged crankpin revealed deep line marks.

d) As per protocol, the crankpin’s hardness and cracks were checked using the MPI method, and no abnormalities were observed.

MPI Test of Caterpillar 3516 Crankshaft	Magnetic Particle Inspection of Caterpillar 3516 Engine

Technical Opinion Taken On the Caterpillar 3516 Crankshaft

Based on the above observations, following inspection, crankpin 07 has sustained serious damage, including localized damage due to bearing failure. It was estimated that the crankpin diameter would need to be reduced by 2.00 to 2.50 mm. The Caterpillar pillar, as the engine manufacturer’s maximum allowable grinding limit for the Caterpillar 3516 crankshaft, is only 1.00 mm; therefore, the crankshaft is deemed rejected. 

Action Taken by RA Power Solutions to Save the Crankshaft of Caterpillar 3516 

The various reports and photographs of the damaged crankpin were carefully studied, and considering that all other parameters, such as hardness, crack detection report, deflection, and runout, were within limits as per the manufacturer’s manual, it was decided to save the crankshaft from rejection by grinding it.

The grinding of crankpin number 07 was executed onsite without removing the crankshaft from the engine block, and it was undersized by 2.00 mm, maintaining a final diameter of 133.00 mm.

Final Surface Finish of Crankpin of Caterpillar 3516 Engine	Caterpillar 3516 Engine Crankshaft after Grinding and Polishing

Supply of Special 2.00 mm Undersized Crankpin Bearings for Caterpillar 3516 by RA Power Solutions

RA Power Solutions, through their principal based in the UK, developed 2.00 mm undersized crankpin bearings for the Caterpillar 3516. These bearings have been supplied to the client, and the engine has since been commissioned and is performing satisfactorily.  

For more information regarding crankshaft grinding services, please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.