Working Card |
Separation of Piston and Connecting Rod |
506-01.05 |
Page 1 (2) |
Edition 01H |
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L23/30H |
08028-0D/H5250/94.08.12
Safety precautions:
Stopped engine
Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.
Description:
Separation of piston and connecting rod for inspection or/and overhaul.
Assembly of piston and connecting rod after inspection or/and overhaul.
Starting position:
Piston and connecting rod are dismounted
from engine |
506-01.00 |
Related procedure: |
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Inspection or/and overhaul of piston |
506-01.10 |
Inspection or/and overhaul of |
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connecting rod |
506-01.15 |
Inspection of connecting rod |
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big-endbearing |
506-01.16 |
Manpower: |
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Working time |
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1/4 |
hour |
Capacity |
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1 |
man |
Data: |
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Data for pressure and tolerance |
(Page 500.35) |
Data for torque moment |
(Page 500.40) |
Declaration of weight |
(Page 500.45) |
Special tools: |
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Plate no |
Item no |
Note |
52006 |
021 |
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52006 |
033 |
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52006 |
200 |
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Hand tools:
Open-end spanner, 24 mm.
Wooden wedge, 2 pieces.
Wooden support.
Wire.
Replacement and wearing parts:
Plate no |
Item no |
Qty/ |
95.50 - ES0S
506-01.05 |
Separation of Piston and Connecting Rod |
Working Card |
Edition 01H |
Page 2 (2) |
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L23/30H
Landing of Piston and Connecting Rod
1) Land the piston and connecting rod carefully on wooden supports to prevent damage of piston and scraper ring, see fig 1.
6) Take out the securing ring, (seeger circlips), push out the piston pin and lift the connecting rod away.
Assembly of Piston and Connecting Rod
7)For assembly of piston and connecting rod, see point 1-6 in reversed order.
8)Lubricate the piston pin before assembling.
Fig 1. Landing of Piston and Connecting Rod.
2) The bearing cap should be mounted with the screws tightened only by hand, in order to protect the serrated joint faces during handling of the assembly, see fig 1.
3) Remove the shackle and eye screw from the piston crown, see fig 1.
4) Place the piston and connecting rod assembly in upright position resting on the top face of the piston crown, see fig 2.
Note: Wooden wedges should be used to prevent the connecting rod from swinging out and thus impact the piston skirt during the lifting into upright position.
5) Place a wire around the big-end of the connecting rod. Attach a tackle and tighten the wire rope, see
fig 2. |
Fig 2. Removal of Connecting Rod and Piston Pin. |
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Separation of Piston and Connecting Rod |
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08028-0D/H5250/94.08.12
95.50 - ES0S
Working Card |
Piston |
506-01.10 |
Page 1 (4) |
Edition 01H |
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L23/30H |
08028-0d/H5250/94.08.12
Safety precautions:
Stopped engine
Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.
Description:
Cleaning and inspection of piston. Control of piston ring, scraper ring and ring grooves.
Starting position: |
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Piston has been dismantled from |
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connecting rod |
506-01.05 |
Related procedure: |
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Mounting of piston and |
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connecting rod |
506-01.20 |
Manpower: |
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Working time |
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1/2 |
hour |
Capacity |
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1 |
man |
Data: |
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Data for pressure and tolerance |
(Page 500.35) |
Data for torque moment |
(Page 500.40) |
Declaration of weight |
(Page 500.45) |
Special tools: |
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Plate no |
Item no |
Note |
52006 |
141 |
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52006 |
153 |
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52006 |
165 |
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Hand tools:
Tools for cleaning of piston, steel brush, scraper etc.
Replacement and wearing parts:
Plate no |
Item no |
Qty/ |
95.50 - ES0S
506-01.10 |
Piston |
Working Card |
Edition 01H |
Page 2 (4) |
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L23/30H
Removal of Piston Ring
For removal of piston rings, which are to be used again, and for all mounting of rings, only the special ring opener which prevents local over stressing of the rings should be used.
Straps to expand the ring gap or tools working on the same principle must not be used, as this would result in permanent deformation which might cause blowby or broken rings.
Inspection of Piston
1)Remove the piston and scraper rings.
2)Cleanandexaminethepistonringstodetermine if reuse is acceptable, see page 3.
3)Clean the piston on the outside and on the inside.
4)Inspect the piston ring and scraper ring grooves for wear, see page 3.
08028-0d/H5250/94.08.12
95.50 - ES0S
Working Card |
Piston |
506-01.10 |
Page 3 (4) |
Edition 01H |
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The piston has to be scrapped if:
A) The wear limit on the testing mandrel is exceeded, see fig 1A
or
B) The clearance between the new piston/scraper ring and ring groove is exceeded, see fig 1B.
Note! At each piston overhaul:
-The piston and scraper ring must be exchanged.
-The cylinder liner must be honed according to the instructions.
L23/30H
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Piston and oil |
New ring |
Ring grooves. |
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scraper ring. |
grooves. |
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Max. wear limit. |
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Nominal size. |
Tolerances. |
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Piston ring |
New |
4.0 mm |
+0.14 |
4.43 mm |
1 |
4.0 mm |
+0.12 |
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Piston ring |
New |
4.0 mm |
+0.11 |
4.43 mm |
2 |
4.0 mm |
+0.09 |
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Piston ring |
New |
4.0 mm |
+0.11 |
4.43 mm |
3 |
4.0 mm |
+0.09 |
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Scraper ring |
New |
7.0 mm |
+0.10 |
7.43 mm |
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7.0 mm |
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+0.08 |
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Table 1. Nominal size, new ring groove tolerance and wear limit for ring grooves.
A) Testing Mandrel for Ring Grooves |
B) Clearance Ring/Groove |
08028-0d/H5250/94.08.12
If the wear limit (2 mm mark) on the testing mandrel is exceeded, the specified max. wear limits are exceeded, and the piston must be scrapped.
Wear limit line.
The handle is marked with the nominal size.
0.45 mm
Maximum vertical clearance between new piston ring/scraper ring and ring groove: 0.45 mm.
Fig 1. Wear limits for ring grooves.
95.50 - ES0S
506-01.10 |
Piston |
Working Card |
Edition 01H |
Page 4 (4) |
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L23/30H
Position of Piston and Scraper Rings
Piston Ring No 1: marked with ident. No "top 881500-3" or "0946".
Piston Ring No 2: marked with ident. No "top 881502-7" or "0947".
Piston Ring No 3: marked with ident. No "top 881501-5" or "0945".
Scraper ring: marked with ident. No "top 881503-9" or "0120".
Marking of Piston and Scraper Rings
Marking
Identification marks to face upwards against the piston crown when mounted.
Note! The marking may include other figures than mentioned above, for instance trade mark and production codes.
08028-0d/H5250/94.08.12
95.50 - ES0S