ESR 0553
OVERHAUL OF ALCO ENGINE
CRANKSHAFT & FREE END DRIVE
Version 1.0
Issued June 2010
Owner:
Approved
by:
Chief Engineer Rolling Stock
Stephen White,
Technical Specialist Rolling
Stock Performance Standards,
Rolling Stock Access Integrity
Authorised
by:
Michael Uhlig,
Manager,
Rolling Stock Access Integrity
Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.
UNCONTROLLED WHEN PRINTED
Page 1 of 5
Engineering Standard
Engineering Standard
Rolling Stock
RailCorp Engineering Standard — Rolling Stock
Overhaul of ALCO engine crankshaft & free end drive
ESR 0553
Document control
Revision
Date
Summary of change
(RSS 0553) 1.0
August 2007
Based on TRS 1501
(RSS 0553) 1.1
May 2008
References to some RSS standards amended
(ESR 0553) 1.0
June 2010
Reformatted and renumbered ESR 0553
Summary of changes from previous version
Summary of change
Section
NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’
to fit on one page remove the page break between the existing pages 2 and 3.
HOWEVER if the ‘Document control’ page carries over to a second page separate
pages must be used for ‘Contents’ and ‘Document control’
Contents
1 Scope..................................................................................................................................................3
2 General ...............................................................................................................................................3
3 Definitions ..........................................................................................................................................3
4 Special tools ......................................................................................................................................3
5 Disassembly.......................................................................................................................................3
6 Replacement parts ............................................................................................................................3
7 Cleaning .............................................................................................................................................4
8 Inspection and reconditioning procedure ......................................................................................4
9 Assembly............................................................................................................................................5
10 Tolerances..........................................................................................................................................5
11 Performance.......................................................................................................................................5
12 Storage and transportation ..............................................................................................................5
13 Identification ......................................................................................................................................5
14 Referenced standards.......................................................................................................................5
14.1 RailCorp standards ...................................................................................................................5
14.2 Alco documents.........................................................................................................................5
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 2 of 5
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of ALCO engine crankshaft & free end drive
1
ESR 0553
Scope
This standard sets out the minimum requirements, procedures and tests for the overhaul
of Alco 251B-6LS engine crankshaft and free end assembly for 48 class locomotives.
The free end drive assembly consists of the extension shaft, oil seal, drive gear and
vibration damper.
2
General
This instruction is to be used in conjunction with Alco Maintenance Instructions MI's
11008, 11012, 11030, and 11074 and Spare Parts Manual DRP 11903 and 11925 to the
latest revision, unless specified otherwise, to provide clarification, amplification and
additional requirements where necessary.
Drawings, specifications, standards and maintenance instructions are referred to without
amendment suffixes or dates of issue. This standard/instruction therefore shall be used in
conjunction with all applicable drawing issues, specifications and other documents
current at the time of inquiry.
Record sheets for stripdown, rebuild tolerances and clearances shall be completed and
supplied to the Purchaser.
Diagram 1 Engine crankshaft
3
Definitions
OEM is an abbreviation for Original Equipment Manufacturer.
MI is an abbreviation for Maintenance Instruction
DRP is an abbreviation for Renewal Parts List
4
Special tools
Special tools, gauges and fixtures in accordance with Alco MI's 11008, 11012 and 11074
shall be used during overhaul of the crankshaft and free end drive assembly.
5
Disassembly
The crankshaft, split gear and free end drive assembly shall be removed from the cylinder
block and disassembled in accordance with Alco MI's 11008, 11012 and 11074.
6
Replacement parts
All replacement parts shall be genuine GE-Alco to the latest revision unless otherwise
specified or approved by the Purchaser.
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 3 of 5
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of ALCO engine crankshaft & free end drive
ESR 0553
It is mandatory to replace the following components:
• Nut, hug lock
Alco P/N 21513727,
3 off
• Nut, hug lock
Alco P/N 21513728,
9 off
• Lockwire
Alco P/N 2157002
• Gasket, oil seal to base and turbo support
Alco P/N 21526720
• Gasket, oil seal to turbo support
Alco P/N 2152676
Genuine GE-Alco lockwire is not required. Alternative suppliers must be approved by the
Purchaser.
The quantity for replacement parts is one unless indicated otherwise.
All other components are to be replaced on the basis of condition as specified in Alco
MI's 11008, 11012 and 11030.
The crankshaft split gear has straight cut or spur gear teeth. The outer ring is of uniform
thickness.
Crankshaft journals and pins may be reclaimed by rechroming. Approval must be given
by the Purchaser if a crankshaft is to be reclaimed by rechroming.
Under no circumstances are crankshaft journals to be reclaimed by grinding undersize
(for use with undersized bearings).
7
Cleaning
The crankshaft and free end drive assembly are to be thoroughly cleaned using a
commercial degreaser such as Ardrox 6401M and hand cloth. This is best achieved by
using a special stand which provides support at the No2 and 5 main bearing journals and
allows the crankshaft to be rotated by hand.
All open oil passage ways are to be thoroughly cleaned using a bottle brush and
degreaser. Existing plugs in any passage ways are not to be removed.
8
Inspection and reconditioning procedure
All reusable parts shall be inspected and requalified in accordance with Alco MI's 11008,
11012 and 11074.
Gear teeth condition is to be assessed in accordance with Alco MI 11030. Split gears are
to remain in matched pairs.
The repairer shall develop appropriate inspection report sheets and procedures for use
with this specification. The report shall include a visual inspection of journals and gear
teeth for wear, thermal cracks or scoring. Component dimensions and tolerances shall be
provided. Evidence of a check of oil passages for cleanliness shall be provided.
The crankshaft and split gear shall be checked for fractures using an approved magnetic
particle test in accordance with ESR 0300. Any evidence of fracture(s) is to be reported to
the Purchaser for determination of appropriate action.
Report sheets showing condition, dimensions, clearances and tolerance of components
shall be submitted to the Purchaser. These details will be used for component tracking
and maintenance planning. The sheets shall also indicate those components that exceed
manufacturer’s tolerances or cannot be re-used.
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 4 of 5
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of ALCO engine crankshaft & free end drive
9
ESR 0553
Assembly
The crankshaft and split gear shall be reassembled and installed in accordance with Alco
MI's 11008, 11012 and 11074.
10
Tolerances
During inspection and assembly all required dimensions, clearances, tolerances and
torques are to be as specified in Alco MI's 11008, 11012 and 11074.
11
Performance
The overhauled Alco 251B-6LS engine crankshaft and free end drive assemblies shall be
required to operate reliably for a minimum period of six (6) years.
12
Storage and transportation
If the crankshaft and extension shaft are not to be immediately installed in an engine, all
wearing surfaces are to be lubricated with a preservative coating such as Tectyl 506 or
similar prior to storage. All open oil passages are to be sprayed with a suitable corrosion
inhibitor such as Tectyl 506 or similar and then plugged prior to storage. The crankshaft is
only to be lifted using slings and lifting blocks in accordance with Alco MI 11008. The
crankshaft is to be stored on wooden blocks in a suitable wooden crate which will provide
adequate protection and prevent the crankshaft from tipping over during transportation.
13
Identification
Only the genuine Alco four counterweight crankshaft, 48 Class Alco P/N 2191632-2 is to
be used.
The crankshaft can be identified by the Manufacturers serial number.
14
Referenced standards
14.1
RailCorp standards
ESR 0300 Specification for application of non destructive testing
ESR 0550 Overhaul of 48 class engine assembly
14.2
Alco documents
MI-11008 Alco Instruction Manual, 48 class crankshaft
MI-11012 Alco Instruction Manual, 48 class crankshaft split gear
MI-11030 Alco Instruction Manual, gear teeth inspection
MI-11074 Alco Instruction Manual, crankshaft drive assembly - free end
DRP-11903
Alco Parts List, extension shaft oil seal
DRP-11925
Alco Parts List, 48 class crankshaft vibration damper and extension shaft
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 5 of 5
Version 1.0