Forged Steel Piston PDF

SERIES 60 SERVICE MANUAL
All information subject to change without notice.

6SE483 9610 1996 DETROIT DIESEL CORPORATION From Bulletin 18-60-98 1-259
1.17 PISTON AND PISTON RING
Series 60 engines currently use two types of pistons. Non-premium engines use pistons with cast
iron domes and skirts and open-end connecting rods. Premium engines (identified by the letters
PK in the fifth and sixth positions of the model number) built on or after March 16, 1998 use
pistons with forged steel domes, aluminum skirts, and closed-end connecting rods.
The cast iron cross-head piston is a two-piece piston consisting of a dome and a skirt. The dome
and skirt are held together by the piston pin. Ring grooves are machined in the piston dome. See
Figure 1-220.
1.Piston Pin 6.Compression Ring
2.Piston Skirt 7.Fire Ring
3.Piston Dome and Bushing Assembly 8.Piston Dome
4.Oil Ring Expander 9.Three-piece Bushing
5.Oil Control Ring
Figure 1-220 Cast Iron Piston and Related Parts
NOTE:
Series 60G engine incorporates a different fire ring (3.5 mm) and compression ring. The
compression ring is identified with a purple stripe.
1-260 From Bulletin 18-60-98 6SE483 9610 1996 DETROIT DIESEL CORPORATION
Each piston is fitted with a fire ring, compression ring and one-piece oil control ring with
expander. See Figure 1-221 , and see Figure 1-222.
1.Oil Control Ring 8.Fire Ring *
2.Compression Ring * 9.Piston Dome
3.Fire Ring 10.Oil Ring Expander
4.Piston Dome 11.Oil Control Ring
5.Oil Ring Expander 12.Compression Ring *
6.Oil Control Ring 13.Fire Ring
7.Compression Ring *
* Identification Mark to Face Top of Dome
Figure 1-221 Figure Piston Ring Location
The forged steel cross-head piston is a two-piece piston consisting of a dome and a skirt. The
dome and skirt are held together by the piston pin. Ring grooves are machined in the piston
dome. See Figure 1-222.
1. Piston Pin 5. Oil Ring Expander
2. Piston Skirt 6. Oil Control Ring
3. Snap Ring 7. Compression Ring
4. Piston Dome 8. Fire Ring
Figure 1-222 Forged Steel Piston and Related Parts
Each piston is fitted with a fire ring, compression ring and one-piece oil control ring with
expander.
The fire and compression rings are installed with the football" mark facing up, see
Figure 1-223.
Figure 1-223 Fire and Compression Ring Identification
A one-piece oil control ring is used in the third groove. The expander is of Spira-Lox
construction.
The forged steel piston uses a floating piston pin which rides on the one-piece bushing pressed
into the end of the connecting rod.
The connecting rod and solid-core piston pin do not have drilled center orfices for lubrication.
Oil for lubrication and cooling is supplied by oil spray from piston-cooling nozzles installed at
the bottom of each piston bore.
During engine operation, gas loads pushing down on the piston dome are taken directly by the
piston pin and connecting rod bushing. The piston skirt, being separate, is free from vertical load
distortion. Thermal distortion is also reduced as the piston dome expands. As the connecting rod
swings to one side on the downward travel of the piston, the major portion of the side thrust is
taken by the piston skirt.
1.17.1 Repair or Replacement of Piston and Piston Ring
To determine if repair is possible or replacement is necessary, perform the following procedure.
See Figure 1-224.
Figure 1-224 Flowchart for Repair or Replacement of Piston and Piston Rings
1.17.2 Removal and Cleaning of Piston and Piston Ring
Refer to section 1.18.2 for piston and connecting rod assembly removal procedure.
1.17.3 Disassembly of Piston and Piston Ring
Disassemble the piston and piston rings as follows:
1. Remove the piston rings with tool J 22405-02 . See Figure 1-225.
Figure 1-225 Removal of Piston Rings
NOTICE:
The pin, bushing, shirt and dome must be match-marked to
assure proper position and orientation.
2. Withdraw the piston pin and mark the front of the piston with a paint pencil, so it can be
returned to the correct cylinder location.
3. Perform the following steps on current cast iron piston domes:
[a] Separate the piston skirt from the piston dome. Mark the front of the dome ear and
skirt with a paint pencil, so they can be returned to the correct location.
[b] Remove the piston pin bearings, marking the front of them with a paint pencil, so
they can be returned to the correct location.
NOTE:
The lower pin bore bearings are removed from the pin bore first, by pushing the bearing
legs outward by hand at the split lines from inside the dome saddle ear. The upper
bearing may be held in the bore by oil on the back of the bearing, making removal from
the pin bore by hand difficult.
To avoid personal injury when blow drying, wear adequate
eye protection (safety glasses or face plate) and do not
exceed 276 kPa (40 lb/in.
2
) air pressure.
NOTICE:
Prying between the bearing back and dome bore may damage
the dome saddle bore or raise burrs which will make installation
of new bearings difficult.
DDC recommends that compressed air be directed between the dome pin bore and back of the
bearing at one end until the bearing pops up out of the bearing retaining hole.
1.17.3.1 Inspection of Piston and Piston Rings
Clean the piston and piston rings prior to inspection as follows:
NOTICE:
Do not attempt to clean the piston skirt by glass beading. It will
remove the tinplating. Do not refinish or polish the piston pin.
1. Clean the piston components with fuel oil.
To avoid personal injury when blow drying, wear adequate
eye protection (safety glasses or face plate) and do not
exceed 276 kPa (40 lb/in.
2
) air pressure.
2. Dry the piston components with compressed air.
3. If fuel oil does not remove the carbon deposits, use a chemical solvent that will not harm
the tinplate on the piston skirt.
NOTICE:
After cleaning, do not leave glass beads in the piston dome. Do
not allow the glass beading to contact any area of the piston
pin bushing or pin bore. Glass beading will remove the
tinplating.
4. The piston dome, including the compression ring grooves, is not tin-plated and may be
wire-brushed to remove any hard carbon. Glass beading can be used to clean a piston
dome. Micro Bead Glass Shot MS-M 0.0736-0.1473 mm (.0029-.0058 in.) is
recommended. The machine used for this process must be able to withstand air pressures
of 552-689 kPa (80-100 lb/in.
2
).
NOTE:
Do not wire-brush the piston skirt.
5. Clean the ring grooves with a suitable tool or a piece of an old compression ring that has
been ground to a bevel edge.
6. Clean the inside surfaces of the piston dome and skirt and the oil relief channels in the oil
ring grooves.
Inspect the piston and piston rings as follows:
1. Inspect the piston skirt and dome.
[a] Check the skirt and dome for score marks, cracks, damaged ring grooves or
overheating indications.
[b] If any of these indications are present, replace the piston.
NOTE:
Burn spots may indicate an obstruction in the connecting rod or piston pin oil passage.
2. Inspect the tapered fire ring groove (top) in the piston dome.
[a] Using the piston ring land step gage, J 35884-A or J 38609 , check tapered fire ring
groove. See Figure 1-226.
[b] Insert the center tang of the tool gage into the top piston ring groove ash. See
Figure 1-226.
[c] Hold the tool at a 90 angle to the ring groove to prevent false readings.
[d] With the center tang into the ring groove as far as it will go, there should be no
contact of the piston with the shoulders of the gage. If the gage makes contact at
point A or point B, the fire ring groove is worn beyond usable limits. Check the
groove clearance at 4 spots, at 90 intervals. Measure the ring land parallel to and at
90 to the wrist pin.
[e] If fire ring groove is worn beyond usable limits, replace piston dome.
1.Fire Ring Groove
Figure 1-226 Checking Fire Ring Groove
3. Inspect tapered compression ring groove (second) in the piston dome.
[a] Using piston ring land step gage, check the groove as in the compression ring groove.
[b] If the compression ring groove is worn beyond usable limits, replace piston dome.
4. Inspect the piston pin.
[a] Check the piston pin for fretting, cracking or signs of overheating.
[b] If these are detected, replace piston pin.
[c] Measure piston pin outside diameter. Specifications are listed in Table 1-17.
[d] If piston pin used with a cast iron piston is out of specifications, replace with new
part.
NOTE:
If piston pin used with a cast iron piston is replaced for any reason, the piston pin
bushing for that cylinder must also be replaced.
5. Inspect the piston pin bushings used with cast iron piston as follows:
[a] Check the piston pin bushings for scoring, pitting, flaking, cracking, excessive wear,
or signs of overheating.
[b] If these conditions are present, the bearings must be replaced.
NOTE:
Early second keystone ring (SKR) design piston domes have an integral piston pin
bushing. The piston pin bushing cannot be replaced in these piston domes. If there is
distress to the piston pin bushing, the entire piston dome assembly must be replaced.
NOTICE:
If a piston pin bushing is replaced for any reason, the piston pin
for that cylinder must also be replaced.
6. Inspect the back of the upper bushing.
[a] Check the bushing for excessive fretting.
[b] If excessive fretting is evident, replace all three bushings.
[c] The corresponding fretting in the piston dome can be removed using crocus cloth,
wet with fuel oil.
7. Inspect the edges of the bearings and piston dome pin bore.
[a] Check the edges of the bearing and piston dome pin bore for dents and dings.
[b] If any are found, it is acceptable to remove burrs at the bearings or pin bore edges by
careful filing.
NOTE:
Remove any dirt or debris on the backs of the bearing or dome pin bore that may take
up clearance required for bearing or piston pin installation.
8. If the piston pin used with a forged steel piston is replaced for any reason, the connecting
rod bushing must be inspected for wear before the rod is installed. If the bushing is worn
beyond limits, the connecting rod must be replaced. Refer to section 1.17.3.1 for
connecting rod bushing inspection procedure.
9. Check the cylinder liner and block bore for excessive out-of-round, taper and high spots
which could cause failure of the piston. Specifications are listed in Table 1-15.
10. Check the block bore for excessive out-of-round, taper, and high spots which could cause
failure of the piston. Specifications are listed in Table 1-14.
1.17.4 Assembly of Piston and Piston Rings
Prior to installing the piston rings, the ring gap of each piston ring must be measured.
1. Insert the piston rings inside of the cylinder liner one at a time, using a piston dome
(inserted upside down into the liner) to push the ring down. The piston dome should be
inserted into the liner, to the same depth as the ring being positioned.
2. For the oil control ring, insert the piston dome down into the liner, until the oil control
ring land is just into the liner. This will ensure that the rings are parallel with the top of
the liner, and that they are positioned in the liner within the normal area of ring travel.
3. After the three rings have been positioned in the liner, measure the ring gap of the top
ring with a feeler gage. See Figure 1-227. Remove the ring from the liner after the
measurement is complete.
Figure 1-227 Piston Ring Gap Measurement
4. Repeat this procedure for each ring, and record your measurements. Allowable ring end
gaps are listed in Table 1-6.
Ring Ring End Gap
Fire Ring (2.5 mm [.098 in.] chrome) 0.40 - 0.87 mm (.016 - .034 in.)
Fire Ring (3.5 mm [.138 in.] plasma) 0.51 - 0.87 mm (.020 - .034 in.)
Compression Ring 0.81 - 1.31 mm (.032 - .051 in.)
Oil Control Ring 0.40 - 0.81 mm (.016 - .032 in.)
Table 1-6 Allowable Ring End Gap
Assemble the piston and piston pin rings as follows:
1. Install the ring expander in the oil control ring groove in the piston. See Figure 1-228.
1.Oil Control Ring 3.Piston
2.Oil Control Ring Groove 4.Oil Control Ring Expander
Figure 1-228 Piston Ring Installation
2. Install the oil control ring by hand. See Figure 1-229.
NOTE:
The oil control ring may be installed in either direction.
NOTE:
Install expander into inside diameter groove of ring with expander spring gap located
180 from the oil control ring gap.
Figure 1-229 Oil Control Ring Installation
NOTE:
The oil control ring expander has a white paint stripe. Make sure the paint mark can be
seen after the oil control ring is installed at ring gap.
Install the fire and compression rings as follows:
NOTICE:
To avoid breaking or overstressing the rings, do not spread them
any more than necessary to slip them over the piston dome.
1. Starting with the compression ring (second groove), install the compression ring and fire
ring with tool J 22405-02 . See Figure 1-230. Make sure the identifying dimple on the
rings is installed up, toward the dome of the piston. See Figure 1-223 for ring
identification and locations.
2. Stagger the ring gaps around the piston. See Figure 1-230.
Figure 1-230 Piston Ring Positioning
3. Refer to section 1.18.4 for piston and connecting rod assembly procedure.

Forged Steel Piston PDF

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Forged Steel Piston PDF

Загружено:

Авторское право:

Доступные форматы

SERIES 60 SERVICE MANUAL

All information subject to change without notice.

Вам также может понравиться