Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Piston, Rings
& Liners
Service Training Malaga

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Piston Design

Service Training Malaga

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Function

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Function

Air In - Exhaust Out

Compress Air
Carry Combustion Loads
Support Rings
Carry Thrust Loads
Transfer Load to Wrist Pin
Transfer Heat
Average Combustion Temperatures 1000C

Service Training Malaga

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Ovality

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Bond Testing

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Normal Wear

Thermal Cracks

Service Training Malaga

Lion DVD

AFA I

Piston

CHAPTER: Piston, Rings & and Liners

Normal Wear

Pre chamber style piston

Service Training Malaga

Lion DVD

AFA I

Piston

CHAPTER: Piston, Rings & and Liners

Normal Wear

Light abrasive Scratching

Light adhesive polishing

Service Training Malaga

Lion DVD

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

10

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

System - Operation
Air Inlet
Fuel
Exhaust
Coolant
Lubrication

Service Training Malaga

11

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

High combustion temperature

Air inlet or exhaust

System problems

Service Training Malaga

12

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

High combustion temperature

13

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Over Fueling

Injector Problem

Service Training Malaga

14

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Localized pockets of melting

Advanced Injector timing

Service Training Malaga

15

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

4 Corner seizure

Cooling System
Lube system or
Fuel system problems

Service Training Malaga

16

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Advanced 4 Corner seizure

17

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

4 Corner seizure

Check under crown

Service Training Malaga

18

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Normal Appearance

19

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Spray Jet

20

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Cold Start

Scuff

Service Training Malaga

21

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Excessive Carbon Build up

Poor lubrication
oil maintenance

Service Training Malaga

22

Lion DVD

Piston

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Excessive Carbon Build up

23

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Abrasive wear on piston ring

Abrasive particles in
the intake system

Service Training Malaga

24

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Abrasive wear on piston skirt

Abrasive particles in
the lubrication oil

Service Training Malaga

25

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Abrasive wear

Identify Abrasive

Service Training Malaga

26

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Erosive Wear

Broken Piston Ring

Service Training Malaga

27

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Erosive Wear

Retainer clip failure

Service Training Malaga

28

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Cast Aluminum Fracture

Brittle
Dull Gray
Sparkly, Crystalline
Chevrons
Fatigue
Rubbing
Bright, Polished
Service Training Malaga

29

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Cast Aluminum Fracture

Service Training Malaga

Brittle

30

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Cast Aluminum Fracture

Service Training Malaga

Fatigue

31

Lion DVD

Piston Ring

AFA I

CHAPTER: Piston, Rings & and Liners

Function

Seal Combustion Gas

Control Oil Films
Transfer Heat
Provide Compatible Wear Surface

Service Training Malaga

32

Lion DVD

Piston Ring

AFA I

CHAPTER: Piston, Rings & and Liners

Material

Ductile cast iron

Strong and flexible

Service Training Malaga

33

Lion DVD

AFA I

Piston Ring

CHAPTER: Piston, Rings & and Liners

Hard facing

Hard Facing Either

Electroplated
Plasma Sprayed

Service Training Malaga

34

Lion DVD

Piston Ring

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Hard facing

35

Lion DVD

Piston Ring

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Witness lap

36

Lion DVD

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

37

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Liner

Function

Carry Combustion Loads

Carry Piston Thrust Loads
Provide Ring Sealing Surface
Transfer Heat (2/3 if piston heat)
Provide Replaceable Wear Surface

Service Training Malaga

38

Lion DVD

Liner

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Design

39

Lion DVD

Liner

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Design

40

Lion DVD

Liner

AFA I

CHAPTER: Piston, Rings & and Liners

Case Hardening

~ 0,5
o mm

Service Training Malaga

41

Lion DVD

Liner

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Roll Burnishing

42

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Liner

Honing

good
Service Training Malaga

to much

to less
43

Lion DVD

Liner

AFA I

CHAPTER: Piston, Rings & and Liners

Cavitation Erosion

Problem with coolant

condition

Service Training Malaga

44

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Causes of Corrosive Wear

Operating Too Cool

High Sulfur Fuel
Poor Quality Oil
Polluted Air
Improperly Conditioned Water

Service Training Malaga

45

Lion DVD

AFA I

Liner

CHAPTER: Piston, Rings & and Liners

Corrosion

Acid in oil can attack valve

guides and liners

Service Training Malaga

46

Lion DVD

Liner

AFA I

CHAPTER: Piston, Rings & and Liners

Corrosion

Damage to Cross
hatch honing pattern

Service Training Malaga

47

Lion DVD

Liner

AFA I

CHAPTER: Piston, Rings & and Liners

Corrosion

Problem with coolant

condition

Service Training Malaga

48

Lion DVD

Liner

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Corrosion

49

Lion DVD

Liner

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Corrosion

50

Lion DVD

AFA I

CHAPTER: Piston, Rings & and Liners

Piston, Ring & Liner Defects

Faulty Material
Process Problem
Assembly Error

Service Training Malaga

51

Lion DVD

Piston

AFA I

CHAPTER: Piston, Rings & and Liners

Ring Insert Problem

Bad casting problem

Service Training Malaga

52

Lion DVD

Ring

AFA I

CHAPTER: Piston, Rings & and Liners

Hard face chipping

Bad Assembly

Service Training Malaga

53

Lion DVD

Ring

AFA I

CHAPTER: Piston, Rings & and Liners

Bonding Problem

Plasma sprayed rings

Service Training Malaga

54

Lion DVD

Liner

AFA I

CHAPTER: Piston, Rings & and Liners

Flange Cracking

Improper roll
burnishing

Service Training Malaga

55

Lion DVD

Liner

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Flange Cracking

56

Lion DVD

Liner

Service Training Malaga

AFA I

CHAPTER: Piston, Rings & and Liners

Handling Problem

57