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Home » Blog » Engine Failures » Excessive Main Bearing Clearance Causes, Signs, Precaution and Solution

Excessive Main Bearing Clearance Causes, Signs, Precaution and Solution

Excessive main bearing clearance causes, signs, consequences, solutions, troubleshooting, preventive measures and steps to repair main bearings with timeframe.

Nov 20, 2024

What is excessive main bearing clearance?

Excessive main bearing clearance occurs when the gap between the main bearings and the crankshaft journal exceeds the manufacturer’s specified limits. This condition can lead to a variety of engine performance issues, including increased friction, heat, and potential failure of the engine components. For example, if the gaps are too wide, it can cause the crankshaft to ‘wobble,’ resulting in rapid wear or seizure of the components, illustrating how seemingly minor clearances can lead to dire consequences.

Criticality of the issue:

Excessive clearance can significantly impact the engine’s structural integrity and performance. It leads to reduced oil retention within the bearings, causing increased friction and heat generation. Over time, this can result in rapid wear, overheating, and ultimately, engine failure. In extreme cases, it can cause the crankshaft to wobble or seize, potentially causing catastrophic damage to the engine and reducing its operational lifespan.

Components Involved & Their Role:

Main Bearings: These support the crankshaft, allowing it to rotate smoothly. They ensure proper lubrication and contribute to power transmission.
Crankshaft: The primary component responsible for converting the engine’s power into rotational motion. It interacts directly with the main bearings and operates under high stress.
Lubrication System: Provides the necessary oil to reduce friction between the bearings and the crankshaft, helping to maintain a smooth and efficient operation.

Conditions That Lead to This Issue:

Excessive main bearing clearance can result from several conditions, especially in demanding operational environments like marine, oil & gas, and power generation industries. These conditions include:

Inadequate Lubrication: Insufficient or contaminated oil can prevent proper lubrication, increasing friction and leading to premature wear of the bearings.
Overheating: High operating temperatures, particularly in marine engines or power generation systems under heavy loads, can cause thermal expansion and distortion of bearing surfaces.
Improper Maintenance: Failure to replace worn bearings or adjust clearances according to OEM specifications can exacerbate wear and cause excessive clearance.
Vibration or Misalignment: In marine and oil & gas applications, the constant vibrations and potential misalignment due to rough operating conditions or installation errors can increase bearing wear, leading to excessive clearance.
Load Imbalance: Excessive load or uneven load distribution, especially in high-speed engines or power plants, can put additional stress on the bearings, leading to accelerated wear and clearance issues.

What Would Cause the Excessive Main Bearing Clearance ?

Wear and Tear: Over time, the bearings and crankshaft surfaces can degrade due to friction and inadequate lubrication.
Improper Installation: Incorrect fitting of bearings during assembly can lead to inconsistent clearances.
Oil Contamination: Contaminants in the oil can accelerate wear on the bearing surfaces.
Heat Damage: Excessive operating temperatures can cause materials to expand and wear down.
Engine Overhaul Errors: Inadequate or incorrect machining during rebuilding can result in poor tolerances.
Poor Lubrication: Insufficient oil supply or low oil pressure can lead to rapid bearing wear.

Symptoms/Signs of the Excessive Main Bearing Clearance

Increased Engine Noise: A knocking or tapping sound may indicate excessive clearance.
Low Oil Pressure: Symptoms of low oil pressure can be due to increased clearances allowing oil to bypass bearings.
Engine Vibration: Unusual vibrations may occur from imbalanced crankshaft rotation.
Oil Discoloration: Dark or dirty oil can indicate contamination or excessive wear.
Metal Shavings in Oil: The presence of metallic debris signals significant bearing wear.

Consequences of the Excessive Main Bearing Clearance

The crankshaft damage can be as below:

Bearing Failure: Worn bearings may experience catastrophic failure, resulting in loss of engine components.
Loss of Power: Reduced contact between bearings and crankshaft diminishes power transfer efficiency.
Complete Engine Failure: If not addressed, excess clearance can lead to total engine seizure and irreparable damage.

Troubleshooting and Actions to Be Taken in Case of the Excessive Main Bearing Clearance

Visual Inspection: Check for metal shavings and oil condition to identify potential wear.
Measure Clearance: Use a micrometer or feeler gauge to assess bearing clearance.
Check Oil Pressure: Validate that the oil pressure is within the manufacturer's specifications.
Inspect Lubrication System: Assess the condition of oil pumps and lines for obstructions or wear.
Review Service History: Look into previous repair or maintenance records for recurring issues.

Solution for Excessive Main Bearing Clearance

To effectively address excessive main bearing clearance, a comprehensive approach is essential. This includes thoroughly inspecting the engine, replacing worn bearings with appropriately sized ones, and adjusting the clearances to align with the manufacturer’s specifications. Equally important is identifying and rectifying underlying issues, such as oil supply deficiencies or contamination, to prevent a recurrence. Resolving these problems demands a high level of precision and expertise, as even minor oversights can lead to significant complications.

With 3 decades of experience and having worked across 30+ countries, we deliver on-time, end-to-end repair and overhaul services across the following assets.

Here are step-by-step instructions on how to Adjust Main Bearing Clearance

1. Obtain Specifications: Refer to the engine manual for the manufacturer’s allowable clearances.
2. Remove Crankshaft: Disassemble the engine to access the main bearings and crankshaft.
3. Inspect Bearings: Check the condition of bearings for signs of wear or damage.
4. Select Thicker Bearings: If necessary, choose bearings with a thicker shell to reduce clearance.
5. Reassemble Engine: Replace the crankshaft and main bearings while ensuring proper alignment.
6. Measure Clearance Again: After assembly, re-measure to ensure that clearances fall within acceptable limits.

Precautionary Measures for Excessive Main Bearing Clearance

Regular Maintenance: Schedule routine oil changes and inspections to prevent wear.
Quality Lubricants: Use high-quality motor oil to ensure optimal lubrication. To extend the life of lube oil and maintain its quality, our advanced Oil Quality Management Solution with an Oil Filtration System and Oil Condition Monitoring can help you with it.
Monitor Operating Temperatures: Keep an eye on engine temperature to avoid overheating.
Follow Assembly Procedures: Adhere strictly to manufacturer guidelines for assembly and repairs.
Use Proper Tools: Use calibrated measuring tools for accurate assessments of clearance.
Remote Monitoring: Implement remote condition monitoring systems to detect changes in bearing performance. You can leverage our Engine Condition Monitoring System, Vib360, to detect engine faults early, reducing maintenance costs and preventing costly breakdowns.

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