piston rings & liners1
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1Service Training Malaga
AFA ILion DVD CHAPTER: Piston, Rings & and Liners
Piston, Rings & Liners
2Service Training Malaga
AFA ILion DVD
Piston Design
CHAPTER: Piston, Rings & and Liners
3Service Training Malaga
AFA ILion DVD
Piston Function
CHAPTER: Piston, Rings & and Liners
4Service Training Malaga
AFA ILion DVD
• Air In - Exhaust Out• Compress Air• Carry Combustion Loads• Support Rings• Carry Thrust Loads• Transfer Load to Wrist Pin• Transfer Heat• Average Combustion Temperatures 1000°C
Piston Function
CHAPTER: Piston, Rings & and Liners
5Service Training Malaga
AFA ILion DVD
Piston Ovality
CHAPTER: Piston, Rings & and Liners
6Service Training Malaga
AFA ILion DVD
Piston Bond Testing
CHAPTER: Piston, Rings & and Liners
7Service Training Malaga
AFA ILion DVD
Piston Normal Wear
Thermal Cracks
CHAPTER: Piston, Rings & and Liners
8Service Training Malaga
AFA ILion DVD
Piston Normal Wear
Pre chamber style piston
CHAPTER: Piston, Rings & and Liners
9Service Training Malaga
AFA ILion DVD
Piston Normal Wear
Light abrasive ScratchingLight adhesive polishing
CHAPTER: Piston, Rings & and Liners
10Service Training Malaga
AFA ILion DVD CHAPTER: Piston, Rings & and Liners
11Service Training Malaga
AFA ILion DVD
System - Operation
• Air Inlet• Fuel• Exhaust• Coolant • Lubrication
CHAPTER: Piston, Rings & and Liners
12Service Training Malaga
AFA ILion DVD
Piston High combustion temperature
Air inlet or exhaustSystem problems
CHAPTER: Piston, Rings & and Liners
13Service Training Malaga
AFA ILion DVD
Piston High combustion temperature
CHAPTER: Piston, Rings & and Liners
14Service Training Malaga
AFA ILion DVD
Piston Over Fueling
Injector Problem
CHAPTER: Piston, Rings & and Liners
15Service Training Malaga
AFA ILion DVD
Piston Localized pockets of melting
Advanced Injector timing
CHAPTER: Piston, Rings & and Liners
16Service Training Malaga
AFA ILion DVD
Piston 4 Corner seizure
Cooling SystemLube system or Fuel system problems
CHAPTER: Piston, Rings & and Liners
17Service Training Malaga
AFA ILion DVD
Piston Advanced 4 Corner seizure
CHAPTER: Piston, Rings & and Liners
18Service Training Malaga
AFA ILion DVD
Piston 4 Corner seizure
Check under crown
CHAPTER: Piston, Rings & and Liners
19Service Training Malaga
AFA ILion DVD
Piston Normal Appearance
CHAPTER: Piston, Rings & and Liners
20Service Training Malaga
AFA ILion DVD
Piston Spray Jet
CHAPTER: Piston, Rings & and Liners
21Service Training Malaga
AFA ILion DVD
Piston Cold Start Scuff
CHAPTER: Piston, Rings & and Liners
22Service Training Malaga
AFA ILion DVD
Piston Excessive Carbon Build up
Poor lubrication oil maintenance
CHAPTER: Piston, Rings & and Liners
23Service Training Malaga
AFA ILion DVD
Piston Excessive Carbon Build up
CHAPTER: Piston, Rings & and Liners
24Service Training Malaga
AFA ILion DVD
Piston Abrasive wear on piston ring
Abrasive particles in the intake system
CHAPTER: Piston, Rings & and Liners
25Service Training Malaga
AFA ILion DVD
Piston Abrasive wear on piston skirt
Abrasive particles in the lubrication oil
CHAPTER: Piston, Rings & and Liners
26Service Training Malaga
AFA ILion DVD
Piston Abrasive wear
Identify Abrasive
CHAPTER: Piston, Rings & and Liners
27Service Training Malaga
AFA ILion DVD
Piston Erosive Wear
Broken Piston Ring
CHAPTER: Piston, Rings & and Liners
28Service Training Malaga
AFA ILion DVD
Piston Erosive Wear
Retainer clip failure
CHAPTER: Piston, Rings & and Liners
29Service Training Malaga
AFA ILion DVD
Cast Aluminum Fracture
Brittle • Dull Gray• Sparkly, Crystalline• Chevrons
Fatigue• Rubbing• Bright, Polished
CHAPTER: Piston, Rings & and Liners
30Service Training Malaga
AFA ILion DVD
Cast Aluminum Fracture Brittle
CHAPTER: Piston, Rings & and Liners
31Service Training Malaga
AFA ILion DVD
Cast Aluminum Fracture Fatigue
CHAPTER: Piston, Rings & and Liners
32Service Training Malaga
AFA ILion DVD
Piston Ring Function
• Seal Combustion Gas
• Control Oil Films
• Transfer Heat
• Provide Compatible Wear Surface
CHAPTER: Piston, Rings & and Liners
33Service Training Malaga
AFA ILion DVD
Piston Ring Material
Ductile cast ironStrong and flexible
CHAPTER: Piston, Rings & and Liners
34Service Training Malaga
AFA ILion DVD
Piston Ring Hard facing
Hard Facing Either
•Electroplated
•Plasma Sprayed
CHAPTER: Piston, Rings & and Liners
35Service Training Malaga
AFA ILion DVD
Piston Ring Hard facing
CHAPTER: Piston, Rings & and Liners
36Service Training Malaga
AFA ILion DVD
Piston Ring Witness lap
CHAPTER: Piston, Rings & and Liners
37Service Training Malaga
AFA ILion DVD CHAPTER: Piston, Rings & and Liners
38Service Training Malaga
AFA ILion DVD
• Carry Combustion Loads
• Carry Piston Thrust Loads
• Provide Ring Sealing Surface• Transfer Heat (2/3 if piston heat)
• Provide Replaceable Wear Surface
Liner Function
CHAPTER: Piston, Rings & and Liners
39Service Training Malaga
AFA ILion DVD
Liner Design
CHAPTER: Piston, Rings & and Liners
40Service Training Malaga
AFA ILion DVD
Liner Design
CHAPTER: Piston, Rings & and Liners
41Service Training Malaga
AFA ILion DVD
Liner Case Hardening
o~ 0,5 mm
CHAPTER: Piston, Rings & and Liners
42Service Training Malaga
AFA ILion DVD
Liner Roll Burnishing
CHAPTER: Piston, Rings & and Liners
43Service Training Malaga
AFA ILion DVD
Liner Honing
good to much to less
CHAPTER: Piston, Rings & and Liners
44Service Training Malaga
AFA ILion DVD
Liner Cavitation Erosion
Problem with coolantcondition
CHAPTER: Piston, Rings & and Liners
45Service Training Malaga
AFA ILion DVD
• Operating Too Cool
• High Sulfur Fuel
• Poor Quality Oil
• Polluted Air
• Improperly Conditioned Water
Causes of Corrosive WearCHAPTER: Piston, Rings & and Liners
46Service Training Malaga
AFA ILion DVD
Liner Corrosion
Acid in oil can attack valve guides and liners
CHAPTER: Piston, Rings & and Liners
47Service Training Malaga
AFA ILion DVD
Liner Corrosion
Damage to Cross hatch honing pattern
CHAPTER: Piston, Rings & and Liners
48Service Training Malaga
AFA ILion DVD
Liner Corrosion
Problem with coolantcondition
CHAPTER: Piston, Rings & and Liners
49Service Training Malaga
AFA ILion DVD
Liner Corrosion
CHAPTER: Piston, Rings & and Liners
50Service Training Malaga
AFA ILion DVD
Liner Corrosion
CHAPTER: Piston, Rings & and Liners
51Service Training Malaga
AFA ILion DVD
• Faulty Material
• Process Problem
• Assembly Error
Piston, Ring & Liner DefectsCHAPTER: Piston, Rings & and Liners
52Service Training Malaga
AFA ILion DVD
Piston Ring Insert Problem
Bad casting problem
CHAPTER: Piston, Rings & and Liners
53Service Training Malaga
AFA ILion DVD
Ring Hard face chipping
Bad Assembly
CHAPTER: Piston, Rings & and Liners
54Service Training Malaga
AFA ILion DVD
Ring Bonding Problem
Plasma sprayed rings
CHAPTER: Piston, Rings & and Liners
55Service Training Malaga
AFA ILion DVD
Liner Flange Cracking
Improper roll burnishing
CHAPTER: Piston, Rings & and Liners
56Service Training Malaga
AFA ILion DVD
Liner Flange Cracking
CHAPTER: Piston, Rings & and Liners
57Service Training Malaga
AFA ILion DVD
Liner Handling Problem
CHAPTER: Piston, Rings & and Liners
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