Daihatsu 8-DK32 Crankshaft Repair on Vessel While Sailing from Bahamas to Norfolk, USA

RA Power Solutions recently completed the repair of a broken crankshaft of a **Daihatsu 8-DK32 diesel engine** during the vessel’s voyage from the Bahamas to Norfolk, USA.

The repair was performed on board the vessel without removal of the crankshaft from the engine. This avoided the vessel incurring a lengthy delay and the expense of removing and transporting the crankshaft to a workshop.

The main specifications of the crankshaft/engine of the Daihatsu 8-DK32 are as follows:

Crankshaft Damage and Inspection

An old client from Athens, Greece, contacted RA Power Solutions with a serious bearing seizure problem in the Daihatsu 8-DK32 auxiliary engine.

Two experienced RA Power Solutions technicians boarded the vessel in the Bahamas port and inspected the crankshaft.

Inspection revealed that **crankpin bearings **of crankpin №02 and crankpin №06 were severely damaged due to seizure.

Dimensional inspection was performed in detail. The following ovalities have been found:

Crankpin ovality no. 02–1.23 mm

Crankpin №06 — Ovality of 0.70 mm

The crankshaft hardness was checked and found to be within acceptable limits with a slight variation.

A magnetic particle inspection (MPI) was also conducted to look for cracks. The damaged crankpins did not show any cracks.

Damage of crankpin no. 02 of Daihatsu 8-DK32

Before grinding and polishing of crankpin no. 06

Hardness check of crankpin no. 02 before grinding

Crack detection test of Daihatsu 8-DK32 Crankshaft before grinding

Crankshaft Deflection Check

It was important to check crankshaft deflection, as two crankpin bearings had seized.

The full crankshaft was checked to ensure that the bearing seizure did not cause any major misalignment or change in the crankshaft condition.

The deflection readings were within the permissible limits.

The other crankpins were also examined. They had rough surface marks and bearing line marks, so it was decided to polish them out.

Crack detection by Magnetic Yoke of Daihatsu 8-DK32 crankpin

Daihatsu 8-DK32 crank pin grinding after inspection of crankshaft

Crankpin no. 02 of Daihatsu 8-DK32 after Repair

Picture showing Crank Pin no. 06 after Machining and Grinding

On-Site Grinding of Daihatsu 8-DK32 Crankpins

Damaged crankpins were repaired using **onsite crankshaft grinding equipment**.

Crankpin no. 02 was ground undersized by 1.50 mm, and crankpin no. 06 was ground undersized by 1.00 mm.

The damaged filet radius was also carefully machined and brought back to the required original profile.

After being ground, the crankpins were inspected for dimensions and surface condition.

The other crankpins were polished, not ground, to improve the surface finish and remove bearing marks.

Repair Completed While the Vessel Was Sailing

The entire repair work was completed while the vessel was sailing from the Bahamas to Norfolk, USA.

The vessel carried the required 1.0 mm and 1.5 mm undersized bearings. After the crankshaft grinding and polishing work had been done, the engine was assembled in front of our technicians.

The engine was tested, and it proved satisfactory.

This repair is a good example of how onsite crankshaft grinding can help to repair a damaged crankshaft without removing the complete engine or crankshaft from the vessel.

On-Site Crankshaft Repair Services

**RA Power Solutions** has a team of experienced technicians who can be deputed on short notice for crankshaft inspection, grinding, polishing, and repair works.

Our technicians have performed crankshaft repair work on marine and industrial engines in various locations around the world. Crankshaft Grinding On-Site On-site crankshaft grinding can be done when it is difficult, expensive, or likely to cause a long downtime to remove the crankshaft from the engine.

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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, the United Arab Emirates, Qatar, Italy, UK, Kuwait, Iran, Iraq, Turkey, Italy, United Kingdom, Germany, England, United Kingdom, United Kingdom, Rome, Canada, Australia, Bangladesh, Canada, Dubai, Greece, Haiti, Hong Kong, Indonesia, Kenya, Malaysia, Maldives, Kenya, Kuwait, Madagascar, Mexico, Nigeria, Oman, Philippines, Saint Lucia, Saudi Arabia, Singapore, Spain, Sint Maarten, Sri Lanka, Suriname, Thailand, Togo, United Kingdom, United States, Yemen, Zambia.

For crankpin grinding, crankshaft repair, or on-site crankshaft grinding needs, contact RA Power Solutions. Please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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