If we talk about the engine, it is the heart of your vessel and industries, the internal combustion engine, the crankshaft that keeps it alive and working.
The journals of the crankshafts are one of the components with immense importance. A component that ensures smooth rotation and power transmission.
In this blog, we will explore the common causes, symptoms, impacts, and solutions for crankshaft journal damage. Also, what engine crankshaft repair tips should you follow to keep your engine running at its best.
Common causes of journal damage:
A crankshaft journal damage is not something that will happen overnight. Journal damage is a result of your engine getting poor maintenance, being under prolonged stress, or a result of a sudden mechanical failure.
Having a better understanding of what factors led to the damage is the first step towards preventing future happenings. And planning effective engine crankshaft repair.
Here’s a list of the most common causes of crankshaft journal damage:
crankshaft journal damage
1. Insufficient lubrication:
When there is an insufficiency of proper oil flowing through the journals, the metal often gets in contact, i.e. metal-on-metal contact. Which causes scoring, and wear, which ultimately makes it quite difficult for the engine to work.
2. Contaminated oil:
It also happens when you overlook the engine oil’s health. Sometimes, when you don’t change the oil, or clean it, dirt, debris, and even metal particles present in the oil get in the way. And they scratch and erode your crankshaft engine journal surfaces.
3. Overheating:
Your crankshaft journals are also at the verge of getting damaged when the temperature of your engine shoots high. This ultimately weakens your engine crankshaft material and causes surface deformation.
4. Bearing failure:
Your engine crankshaft journal damage is also a result of having worn-out or improperly installed bearings. This usually results in uneven loadings and eventually journal damage.
5. Improper machining:
Improper machining, which means incorrect grinding or polishing at the time of engine rebuilding, can cause irregularities in the mechanism which will eventually harm the crankshaft journals.
Techniques like In-situ Grinding of Crankshaft can help avoid such errors during repair.
Symptoms of journal damage:
You can think of symptoms as your crankshaft engine journal’s way of shouting. ‘Hey, I’m about to break down!’—catch them early before real trouble begins!
Recognizing these symengine crankshaft repair
In-situ Grinding of Crankshaft Symptoms, or signals of journal damage in the early days can help you and save you from a major breakdown.
Here are some common symptoms that your journal surface will show when it’s about to get damaged. It might be time for you to closely inspect the whole situation.
1. Knocking noise:
If you hear a distant knocking sound- people often call it a ‘rod knock’, then maybe it’s time for you to give it a check. This knocking sound usually indicates excessive clearance between the journal and the bearing.
2. Low oil pressure:
When the journals are about to get damaged, or are actually damaged, the oil film thickness reduces significantly. Which causes the oil pressure to drop down, if you notice a drop in your engine oil pressure, you should check the journals before it gets worse.
3. Metal shavings in oil:
Metal debris in the engine oil is because your crankshaft engine journals or bearings are going through scoring and wear. If you find metal chunks during an oil change, do not overlook them.
4. Vibrations:
When something is about to get worse, it starts to vibrate. Engine vibrations, especially at certain RPMs, can be a result of an unbalanced crankshaft due to journal damage.
5. Overheating:
There is an increase in friction when the journals are poorly lubricated. Which ultimately causes an increase in engine temperature.
Impact on engine performance:
When your crankshaft journals are damaged, it is not just a minor issue. This small issue can turn big in no time, hampering your engine’s ability to perform.
Here’s how the damage manifests in real-world performance:
1. Reduced efficiency:
When your journals are damaged, it disrupts the smooth rotation of the crankshaft. Hence, increasing resistance by the journals and reducing the overall engine’s performance.
2. Higher fuel consumption:
A damaged and inefficient engine requires significantly more fuel. In order to operate and produce the same amount of power as a normal engine type.
3. Loss of power:
With regular wear of the journals, it becomes hard for the pistons, and rods to operate optimally. Which in turn leads to a significant drop in horsepower and torque of the engine.
4. Increased emission:
Poor combustion caused by inefficient crankshaft operation results in higher emissions.
5. Complete engine failure:
Overlooking the journal damage can eventually lead to potential engine damage. The engine failure can include factors like- broken crankshafts, seized engines, or shattered blocks. All requiring urgent engine crankshaft repair or full replacement.
Engine Crankshaft Repair and replacement options:
Journal damage is not the end of it or the engine. You can potentially get it fixed, or repaired, or if the condition is at the extreme level, you can get it replaced with a new one. Depending on how severe the situation is, several repair and replacement methods are available to restore engine health:
1. Polishing:
If the condition of your journal is not at the extreme level, and just a few minor scratches, or scoring, you can get it polished. Polishing the journals using a crankshaft polisher is the best way to restore it into a smooth surface.
2. Grinding:
If the damage is more significant, grind the journals into smaller sizes and fit undersized bearings. In-situ Grinding of Crankshaft is a popular method to repair without dismantling the engine.
3. Welding and machining:
When the damage is quite severe, the journals can be repaired, and built up with welding material. And then it can be machined back to its standard or oversize specifications.
4. Crankshaft replacement:
If the damage is extensive and not cost-effective. Then it is better to get the crankshaft replaced with a new or remanufactured one, instead of spending heavily on its repair.
Preventive maintenance tips:
1. Use high-quality oil and filters to prevent oil contamination, and change the oil at regular intervals.
2. Monitor the oil pressure through an oil pressure gauge, and don’t overlook even a slight drop in the oil pressure.
3. Make sure you use manufacturer-recommended bearings and ensure they are installed correctly.
4. Avoid overloading the engine beyond its designed limit, especially when you are towing in a high-performance situation.
5. Make sure you regularly check for potential oil leaks that could lead to lubrication issues.
Conclusion:
You might think crankshaft journal damage is a minor issue, but it has a massive impact on engine performance and longevity.
In this blog, we discussed how crankshaft journal damage affects engine performance and what the potential symptoms are. And what is its impact on engine performance? Also, how can we prevent our crankshaft journals from getting damaged? Proper maintenance and timely engine crankshaft repair using advanced methods like In-situ Grinding of Crankshaft can save you from facing major breakdowns.
FAQs:
1. What causes crankshaft journal damage?
Crankshaft journal damage is mainly caused by Lack of lubrication, dirt in oil, or excessive load.
2. Can a damaged crankshaft journal be repaired?
Yes! If the damage is within the tolerance level, you can go for a crankshaft engine repair through polishing and grinding.
3. How do I know if my crankshaft journals are bad?
Look out for knocking noises and oil pressure warnings.
4. What happens if I ignore journal damage?
Ignoring journal damage can cause bearing failure and engine seizure.
5. How can I prevent crankshaft journal wear?
You can prevent crankshaft journal wear by using good quality oil, changing it regularly, and avoiding over-revving.
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