Engine & Machinery Division 1000, Bangeojinsunhwan-doro Dong-gu, Ulsan, Korea 682-792
Tel No. +82 52 202 7313 24/7 Hot line +1 212 845 9803 Fax No +82 52 202 7581 E-mail:
[email protected]
Service Letter Date : March 11, 2014 Ref. No. : HHI-HSM-SL-14-004 Design history of Piston for H21/32(P) and H25/33(P) Dear Sirs, We have improved the Piston design continuously to ensure the tightening condition between Piston crown and skirt. There are 5 kinds of different Piston design for H21/32(P) and 4 kinds of design for H25/33(P). So, please refer to attached Technical circular and to be kept the right instruction book at a conspicuous place onboard so that the Pistons can be overhauled properly. We hope that above is of service to you. Faithfully yours,
Y. J. Hu, General Manager Engine & Machinery Customer Service Dep’t Engine & Machinery Division Tel. : + 82 52 202 7313 Fax : + 82 52 202 7581 24/7 Hot line : + 1 212 845 9803 E-mail:
[email protected] Hi-Service : http://cs.hyundai-engine.com 1/1
Attachment: 1. Technical circular (DESIGN HISTORY OF PISTON) [The end]
2/1
TECHNICAL CIRCULAR
SUBJECT: DESIGN HISTORY OF PISTON
TYPE: H21/32(P), H25/33(P)
Ref. No.: TEC2014/K2D0 - 001 Date: 28th Jan. 2014
Page 1 of 6
TECHNICAL CIRCULAR
Ref. No.: TEC2014/K2D0 - 001
[ BACKGROUND ] Piston for HiMSEN engine has been improved continuously to ensure the tightening connection between piston crown and skirt. This technical circular shows the design history of piston complete for HiMSEN H21/32(P) and H25/33(P) to help customers’ easier understanding.
[ HISTORY OF MANUAL ] 1. H21/32(P) Connection
Manual (Latest)
Tightening Torque Remark
Type
Washer
Drawing & Part List
Maintenance Procedure
Pre-tightening (Loosen)
Tightening
Test Torque
1 Bolt
Thrust piece
A31100-1B
M31100-1B
130 Nm
45 Nm - 60°
130 Nm
4 Stud
Pressure Washer
A31100-2C
M31100-2E
40 Nm
20 Nm - 60°
45 Nm
Pressure Washer
A31100-3A
M31100-3B
60 Nm
20 Nm - 60°
70 Nm
Nordlock Washer
A31100-4B
M31100-4C
60 Nm
40 Nm - 60°
100 Nm
Nordlock Washer
A31100-5A
M31100-5A
30 / 60 Nm
25 Nm - 90°
100 Nm
Standard for new project (Stationary)
2 Stud
2 Bolt
Standard for new project (Marine Genset & Propulsion)
Figure 1. Shape of Piston Type(H21/32) – 1 Bolt / 4 Stud / 2 Stud / 2 Bolt Page 2 of 6 ENGINE & MACHINERY DIVISION Tel.: +82-52-202-7261, Fax: +82-52-202-7350, E-mail:
[email protected]
TECHNICAL CIRCULAR
Ref. No.: TEC2014/K2D0 - 001
2. H25/33(P) Connection
Manual
Tightening Torque Remark
Type
Washer
Drawing & Part List
Maintenance Procedure
Pre-tightening (Loosen)
Tightening
Test Torque
4 Bolt
Thrust piece
C31100-1B
M31100-1C
90 Nm
30 Nm - 60°
90 Nm
Pressure Washer
C31100-2A
M31100-2B
30 / 70 Nm
30 Nm - 60°
90 Nm
Nordlock Washer
C31100-3A
M31100-3B
30 / 70 Nm
30/70Nm 60°
150 Nm
Nordlock Washer
C31100-4A
M31100-4A
30 / 60 Nm
50 Nm - 90°
160 Nm
Standard for new project (Stationary & Propulsion)
2 Stud
2 Bolt
Standard for new project (Marine Genset)
Figure 2. Shape of Piston Type(H25/33) – 4 Bolt / 2 Stud / 2 Bolt
[ CONSIDERATION OF COMPATIBILITY ] As the shapes of piston bowls of all piston types are same, there is nothing changed except for slightly different piston mass in the engine-generator system. (Maximum deviation of mass is 3.9% for H21/32 case with 4 Stud type and 2 Bolt type.)
Page 3 of 6 ENGINE & MACHINERY DIVISION Tel.: +82-52-202-7261, Fax: +82-52-202-7350, E-mail:
[email protected]
TECHNICAL CIRCULAR
Ref. No.: TEC2014/K2D0 - 001
According to the analysis shown on Table.1 and Fig.2 for the effect of a piston weight unbalance on the dynamic stability of the engine-generator system in terms of natural frequencies, engine dynamic load and engine vibration, the variations were very small and could be neglected. Table 1. Summary of Variation Analysis – 7H21/32
Figure 2. Analysis Result of Effect of Piston Weight Unbalance
Page 4 of 6 ENGINE & MACHINERY DIVISION Tel.: +82-52-202-7261, Fax: +82-52-202-7350, E-mail:
[email protected]
TECHNICAL CIRCULAR
Ref. No.: TEC2014/K2D0 - 001
Figure 2 (continued). Analysis Result of Effect of Piston Weight Unbalance
Therefore, engine operation with combination of other types of piston completes will not cause any problem and is allowed for 7H21/32.
Page 5 of 6 ENGINE & MACHINERY DIVISION Tel.: +82-52-202-7261, Fax: +82-52-202-7350, E-mail:
[email protected]
TECHNICAL CIRCULAR
Ref. No.: TEC2014/K2D0 - 001
In case of other engine types such as 5H, 6H, 8H, 9H21/32 and all H25/33 are also acceptable to use different types of piston completes in same engine according to this analysis result because it was performed at 7H21/32 with 4 Stud and 2 Bolt piston types which is worst case of unbalance condition on the dynamic stability, so it can cover other cases of mass deviation.
Attachment: 1. Manual sheets for H21/32 1) 1 Bolt : A31100-1B / M31100-1B 2) 4 Stud : A31100-2C / M31100-2E 3) 2 Stud (Pressure Washer) : A31100-3A / M31100-3B 4) 2 Stud (Nordlock Washer) : A31100-4B / M31100-4C 5) 2 Bolt : A31100-5A / M31100-5A
2. Manual sheets for H25/33 1) 4 Bolt : C31100-1B / M31100-1C 2) 2 Stud (Pressure Washer) : C31100-2A / M31100-2B 3) 2 Stud (Nordlock Washer) : C31100-3A / M31100-3B 4) 2 Bolt : C31100-4A / M31100-4A
[The end]
Yours sincerely,
___________________________ Y. S. Ryoo / General Manager HiMSEN Medium Bore D&D Dep’t
Page 6 of 6 ENGINE & MACHINERY DIVISION Tel.: +82-52-202-7261, Fax: +82-52-202-7350, E-mail:
[email protected]
Page
H21/32 Piston Assembly
Assembly Drawing & Part List
㋒›⼺ ⍊Ở᮪ᝂ
☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
1/1
Section No.
Rev.
A31100
1B
G 111
114
151 152 153
113 112 110 120
130
A32000
Part List Item No.
Description
Q’ty / Cyl.
Weight (kg)
Remarks / See Note
110
Piston complete
1
24.66
Item no. 111~114
111
Piston crown
1
6.33
112
Piston skirt
1
18.0
113
Thrust piece
1
114
Bolt
1
120
Piston pin complete
1
9.5
130
Retaining ring
2
0.04
151
Compression ring – top
1
0.21
GOE CK36 TOP GROOVE 1
152
Compression ring – 2nd
1
0.18
GOE TOP GROOVE 2
153
Oil scraper ring
1
0.11
GOE GROOVE 3
Marking on piston rings G HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division
07.08/HSYG
H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
Section No.
Page
1/4 Rev.
M31100
1B
G #
#
㋒›⼺# ㋖# ᦥ# ⓮# ᬚ㌊#
Dismantling a Piston Pin and Piston Rings
41
1.
51
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ⍪❚# ᮪ᗳ⍦Ẳ# ᬚ㌊ ㋲ၺ1+# # # # #M31000 # # # # # # # ⓮G “㋒›⼺# ⱺົ゛# ᗲቲ⓮# ᬚ㌊# ”G
shaft from the engine.
ᬖᬚⓚ# ⧎☆㋮₃⎺1,#
OSee “Dismounting of a piston and connecting rod ”
⑊# ❖எᜒ# ㋒›⼺# ⸂ᔒ⑊⍦# Ẻ⯮㋮੶/# ⸂ᖞ┎⍦#
G G PG G G G G G P inG G G G G GM31000 2.
ၾၺ1# ⑊# ❖எ# =#
61
Dismount the piston together with connecting rod
onto a crane.
91.170
91.170
Lifting jig :
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ┧⍛႖⍦Ẳ# ቺ⍊⏂ ᝆ# 㑚/# ⱺົ゛# ᗲቲ# Ṻ㊚ぎ⓮# ▧㋿᠊ⓚ# ᠿ╂# ⻢┊᮪#
Install lifting jig on the piston crown, and hook up
3.
Lift up the piston together with connecting rod shaft from working stand, and slow down the joint
Ꭶဪ# ⒶṂ㋲# ☛ᛮ⒚⍦# ☆₂›ᖓਢ# ๊ᖺ# ༩ဪၺ1# #
faces of connecting rod shaft on the wooden table
#
or the likes carefully.
#
91.170
# # # # # # # # # # # # # #
Fig.1 Dismantling the circlips for piston pin +㋒›⼺# ㋖# Ẳ⸊ᝓ⓮# ᬚ㌊,#
# 71
எᝒ# 4# য┊# ㋒›⼺# ㋖# ⸊ᝓⓚ# ▚# ㊢ᔒ┊⍊ᜒ#
4.
as shown in fig. 1.
Ṃ㋮⎂# ᬚ㌊㋲ၺ1# ㊢ᔒ┊⍊# =# #
81
91.240
㋒›⼺ⓚ# ቺ੶# ┞ဪ# ṗ⍦Ẳ# ㋒›⼺# ㋖ⓚ# ႖ᦿ㌻ ⓒᗲ# ᳧⋚๎ၺ1#
Dismantle circlips for piston pin by means of plier
Plier :
5.
91.240
Take out the piston pin to the opposite side during lifting the piston.
# # #
G HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division
07.08/HSYG
Page
H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
2/4
Section No.
Rev.
M31100
1B
G
# 9
㋒›⼺# ⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ᬚ㌊㋲ၺ1# ㊢ᔒ┊⍊# =# #
6.
91.250
Dismantle piston rings by means of plier. Plier :
91.250 Be sure to use the plier for piston ring.
ቲ# ㋒›⼺# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㌊⌒#
Otherwise, piston rings may damage.
㋿ၞၺ1# எᖝ❖# ⋠ⓒ᠊# ㋒›⼺# ⍦# ἦṗ┊# ṳ# ᾮ# ┞⁋ၞ ၺ1#
:
;
⎆ἢ⚧# ྡྷ⍊# ᬯⓖ# Ⰺ# ⾊▗ᣒⓚ# ㋒›⼺# ㋒›⼺#
7.
# ㏞⍦Ẳ# ▲ਆ㋲# 㑚/# ᠾቶ# ᬖ㈞ቺⓚ# ෭┊# ၼ⋚
piston ring grooves, and clean all the parts
๎ၺ1# #
carefully.
㋒›⼺⍦# ᯚ▫ṗ▗┎# 㓶❧┊# ┞ဪ# ❖ᜒ# ┦Ỏ㔞# ਖ
8.
Inspect the piston for any abnormal marks carefully.
Ṃ㋲ၺ1# <
Remove burned carbon deposits from piston and
㋒›⼺# ㋖# ἢၾᬖ# ᬖᜒ# ▦ਖ㋲ၺ1#
9.
Inspect the piston pin and the small end bush. (See “Small end bush overhaul” in
+# # # # # M32130 # # # # # # # # # ⓮# “ἢၾᬖ# ᬖ⓮# ᬚ㌊2▦ਖ# ”# ᬖᬚ
M32130 )
ⓚ# ⧎☆㋮₃⎺1,#
㋒›⼺# ᪒ぎ# ┎┻ফᅚ⓮# ▦ਖ#
Inspection of Piston Bolt Tension
41
1.
எᝒ# 5⏖# য┊# ㋒›⼺# ᪒ぎᜒ# ⼶⸂# ›ゾພᗲ# ㈖⍊๎#
dismount piston crown as shown in fig. 2.
㑚# ㋒›⼺⓮# ⸂ᔒ⑊ⓚ# ᬚᝂ㋲ၺ1#
皦畲 枪砮嘎 : 51
91.810
Loosen piston bolt by using a torque spanner and
᪒ぎ⓮# ฮṂṆ# ᦥ# ▧⪟᠊ⓚ# “ᡆᝂ⳪ቲ# ㄮ┊›ぎ# Jq#
91.810
Torque spanner :
(昦痣斲檗)
2.
(Optional)
Coat thread and contact surface of bolt with
soxv”ᗲ# ᦪᜎ# 㑚⍦# ㋒›⼺# ᪒ぎᜒ# 463# Qp⓮# ⼶⸂ᗲ#
“Molycote-paste Gn plus”, and then tighten the bolt
⩊㋲ၺ1#
with a torque of 130 Nm.
# # # # # # # # # # # # # # # ᪒ぎ⓮# ┊খ# :916# pp# ┊㋮┊᠊# ㋒›⼺# ᪒ぎᜒ# ╂Ṃ㋶# ᾮ# ┞⁋ၞၺ1#
If only the length of bolt is less than 76.3 mm, reuse the piston bolt.
M8
Fig.2 Cross section of piston complete +㋒›⼺# ၾ᠊ᅚ,#
G HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division
07.08/HSYG
Page
H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
3/4
Section No.
Rev.
M31100
1B
G 61
᪒ぎᜒ# ၺ# ㈖੶# า# 㑚# 78# Qp⓮# ⼶⸂ᗲ# ၺ# ☆
3. Loosen the bolt again, and tighten the bolt with a torque of 45 Nm.
┎ၺ1# 71
⬪খ▗ⓒᗲ# 93㖡ᜒ# ც# ☆┎ၺ1#
4.
Continue tighten the piston bolt by additional 60ȋ .
# Make sure that the bolt is not rotated
᪒ぎဪ# ㍮# ⼶⸂# 463# Qpᜒ# ▗㋮⎂# ც#
by application of test torque 130 Nm to tightening
┊ṗ# ☆⎂❖❖# ⋠⋚⌒# ㋿ၞၺ1# #
direction.
#
If the bolts can turn any more, replace
# # # # # # # # # # # # # # # ᪒ぎখ# ☆ஞ┊ᔒᅚ# 㐢▚ⓚ# ㋮᠊/# Ṟᗲ⑊# ᪒
by new one.
ぎᗲ# ૦⩊㋮₃⎺1#
㋒›⼺# ㋖# ᦥ# ⓮# ☆ᝓ#
Assembling of Piston Pin and Piston Rings
41
1.
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ☆ᝓ㋮ெ# ▚/# ㋒›⼺#
Coat the surface of piston pin and small end bush
㋖⓮# ㇲ᠊# ᦥ# ἢၾᬖ# ᬖ⍦# ෭㋲# ⎺┒ⓚ# ᦪᜎ# 㑚#
with clean lubricating oil before assembling piston
㋒›⼺# ㋖ⓚ# ᬖ# ἣⓒᗲ# ฒ③# ູဪၺ1#
and connecting rod shaft, and then mount piston pin into small end bush.
#
Make sure that the mark “E” on the
㋒›⼺# ṗᬖ⍦# ㇲᆲ# “H”# ⸂ᜒ# ᧆெ⮷ⓚ#
top of the piston should be positioned in exhaust
㌻㋮ᅚᗳ# ㋲# 㑚# ☆ᝓ㌊⌒# ㋿ၞၺ1# #
side.
#
51
㋒›⼺# ㋖# Ẳ⸊ᝓⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ┻
2.
Mount circlips for piston pin by means of plier.
⦿㋲ၺ1# ㊢ᔒ┊⍊# =# #
61
91.240
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ⸂ᖞ┎ⓚ# Ṃ㋮⎂#
Plier :
3.
91.240
Lift up the piston together with connecting rod
ቺ⍊# ⏂ᝆၺ1#
shaft by means of a crane.
㋒›⼺# ⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ㋒›⼺# # 4.
Mount piston rings into its grooves by means of
㏞⍦# ☆ᝓ㋲ၺ#
the plier.
# 71
㊢ᔒ┊⍊# =# #
91.250
Plier :
91.250
# # # # # # # # # # # # # # # ㋒›⼺# ⓮# ㋲⡓# ᠊⍦# Ṟਾ❚# “wrs”# ⸂ᜒ# ㏫┎㋲# 㑚/# ⸂খ# ㏞⓮# ⒚⡓ⓚ# ㌻㋮ᅚᗳ# ㌊⌒# ㋿ၞၺ1# # # # # # # # # # # # # # # গ# ㋒›⼺# ⓮# ෳၾ# ৃ┊# Ẳᗲ# 453㖡খ# ᆮ ᅚᗳ# ᧆ⯮⸺₃⎺1#
“Top” mark of piston rings should be assembled in upper side of groove. The end gap of each piston ring should be arranged in 120ȋ in relation to each other.
G HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division
07.08/HSYG
H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
Section No.
M31100
Page
4/4 Rev.
1B
G 81
㋒›⼺# ⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ㋒›⼺# # 5.
Mount piston rings into its grooves by means of the
㏞⍦# ☆ᝓ㋲ၺ#
plier.
㊢ᔒ┊⍊# =# #
91.250
Plier :
91.250
#
91
ၺ1#
:1
6. Inspect the piston rings for wear carefully as
எᝒ# 6# য┊# ㋒›⼺# ┊# ᠾᆮ⍞ဪ❖ᜒ# ㏫┎㋲
shown in fig. 3.
G09200
G09200
# # # # # # # # # # # # # # ㋒›⼺# ┊# ᠾ# ▲㋲⯮ᜒ# ⪞㋮⎖ਆฮ# ㋒
If piston rings exceed the wear limit
›⼺# ⍦# ᯚ▫ṗ▗┎# 㓷❧┊# ┞ၺ᠊/# Ṟ# ᬖ㈞ⓒᗲ# ૦⩊㋮₃
and/or if the piston has any abnormal mark, then
⎺1#
replace by new one.
7. Mount the piston together with connecting rod
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎ# ┒⩊ᜒ# ⍪❚⍦# ╂㋲ ၺ1#
shaft into the engine.
+# # # # # M31000 # # # # # # # # # ⓮# “㋒›⼺# ⱺົ゛# ᗲቲᜒ# ⁺ᝆც#
(See “Mounting of a piston and connecting rod into
ᔒ┊ພ⍦# ☆ᝓ# ”# ᬖᬚⓚ# ⧎☆㋮₃⎺1,#
the cylinder liner” in
M31000 )
G G
Fig.3 The maximum vertical clearance of piston rings +㋒›⼺# ⓮# ⫲႖# ᾮ❗# ぞṞ,#
Marking on piston rings 1) 1st ring: GOE CK36 TOP GROOVE 1 2) 2nd ring: GOE or GOE TOP GROOVE 2 3) Oil scraper ring: GOE or GOE GROOVE 3
G HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division
07.08/HSYG
Page
H21/32 Piston Assembly
Assembly Drawing & Part List
㋒›⼺ ⍊Ở᮪ᝂ
☆ᝓᅚ ᦥ ᬖ㈞ ᝂ›ぎ
1/1
Section No.
Rev.
A31100
2C
G 113
111
110
151 152
117
153
116
114 112
115
120
130
M32000
Part List Item No.
Description
Q’ty/Cyl.
Weight (kg)
Remarks / See Note
110
Piston complete
1
24.27
Item no. 111~117
111
Piston crown
1
8.15
112
Piston skirt
1
15.85
113
Stud bolt
4
0.04
114
Pressure washer
4
0.01
115
Hexagon nut
4
0.02
116
O-ring
1
117
Spring pin
1
120
Piston pin complete
1
9.5
130
Retaining ring
2
0.04
151
Compression ring – top
1
0.21
GOE CK36 TOP GROOVE 1
152
Compression ring – 2nd
1
0.17
GOE TOP GROOVE 2
153
Oil scraper ring
1
0.11
GOE GROOVE 3
Marking on piston rings G HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division
07.07/HSYG
H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
Section No.
Page
1/4 Rev.
M31100
2E
G #
#
㋒›⼺# ㋖# ᦥ# ⓮# ᬚ㌊#
Dismantling a Piston Pin and Piston Rings
41
1.
51
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ⍪❚# ᮪ᗳ⍦Ẳ# ᬚ㌊ ㋲ၺ1+# # # # #M31000 # # # # # # # ⓮G “㋒›⼺# ⱺົ゛# ᗲቲ⓮# ᬚ㌊# ”G
shaft from the engine.
ᬖᬚⓚ# ⧎☆㋮₃⎺1,#
OSee “Dismounting of a piston and connecting rod ”
⑊# ❖எᜒ# ㋒›⼺# ⸂ᔒ⑊⍦# Ẻ⯮㋮੶/# ⸂ᖞ┎⍦#
G G PG G G G G G P inG G G G G GM31000 2.
ၾၺ1# ⑊# ❖எ# =#
61
Dismount the piston together with connecting rod
onto a crane.
91.170
91.170
Lifting jig :
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ┧⍛႖⍦Ẳ# ቺ⍊⏂ ᝆ# 㑚/# ⱺົ゛# ᗲቲ# Ṻ㊚ぎ⓮# ▧㋿᠊ⓚ# ᠿ╂# ⻢┊᮪#
Install lifting jig on the piston crown, and hook up
3.
Lift up the piston together with connecting rod shaft from working stand, and slow down the joint
Ꭶဪ# ⒶṂ㋲# ☛ᛮ⒚⍦# ☆₂›ᖓਢ# ๊ᖺ# ༩ဪၺ1# #
faces of connecting rod shaft on the wooden table
#
or the likes carefully.
#
91.170
# # # # # # # # # # # # # #
Fig.1 Dismantling the circlips for piston pin +㋒›⼺# ㋖# Ẳ⸊ᝓ⓮# ᬚ㌊,#
# 71
எᝒ# 4# য┊# ㋒›⼺# ㋖# ⸊ᝓⓚ# ▚# ㊢ᔒ┊⍊ᜒ#
4.
as shown in fig. 1.
Ṃ㋮⎂# ᬚ㌊㋲ၺ1# ㊢ᔒ┊⍊# =# #
81
91.240
㋒›⼺ⓚ# ቺ੶# ┞ဪ# ṗ⍦Ẳ# ㋒›⼺# ㋖ⓚ# ႖ᦿ㌻ ⓒᗲ# ᳧⋚๎ၺ1#
Dismantle circlips for piston pin by means of plier
Plier :
5.
91.240
Take out the piston pin to the opposite side during lifting the piston.
# # #
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H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
2/4
Section No.
Rev.
M31100
2E
G
# 9
㋒›⼺# ⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ᬚ㌊㋲ၺ1# ㊢ᔒ┊⍊# =# #
6.
91.250
Dismantle piston rings by means of plier. Plier :
91.250 Be sure to use the plier for piston ring.
ቲ# ㋒›⼺# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㌊⌒#
Otherwise, piston rings may damage.
㋿ၞၺ1# எᖝ❖# ⋠ⓒ᠊# ㋒›⼺# ⍦# ἦṗ┊# ṳ# ᾮ# ┞⁋ၞ ၺ1#
:
;
⎆ἢ⚧# ྡྷ⍊# ᬯⓖ# Ⰺ# ⾊▗ᣒⓚ# ㋒›⼺# ㋒›⼺#
7.
# ㏞⍦Ẳ# ▲ਆ㋲# 㑚/# ᠾቶ# ᬖ㈞ቺⓚ# ෭┊# ၼ⋚
piston ring grooves, and clean all the parts
๎ၺ1# #
carefully.
㋒›⼺⍦# ᯚ▫ṗ▗┎# 㓶❧┊# ┞ဪ# ❖ᜒ# ┦Ỏ㔞# ਖ
8.
Inspect the piston for any abnormal marks carefully.
Ṃ㋲ၺ1# <
Remove burned carbon deposits from piston and
㋒›⼺# ㋖# ἢၾᬖ# ᬖᜒ# ▦ਖ㋲ၺ1#
9.
Inspect the piston pin and the small end bush. (See “Small end bush overhaul” in
+# # # # # M32130 # # # # # # # # # ⓮# “ἢၾᬖ# ᬖ⓮# ᬚ㌊2▦ਖ# ”# ᬖᬚ
M32130 )
ⓚ# ⧎☆㋮₃⎺1,#
㋒›⼺# ᪒ぎ# ┎┻# ▦ਖ#
Inspection of Piston Bolt Tension
41
1.
எᝒ# 5⏖# য┊# ㋒›⼺# ›⻆ቲᜒ# ⼶⸂# ›ゾພᗲ# ㈖⍊
dismount piston skirt as shown in fig. 2.
๎# 㑚# ㋒›⼺⓮# ›ⱺぎᜒ# ᬚᝂ㋲ၺ1#
皦畲 枪砮嘎 : 51
91.810
91.810
Torque spanner :
(昦痣斲檗)
›⻆ቲ⓮# ฮṂṆ# ᦥ# ▧⪟᠊ⓚ# “ᡆᝂ⳪ぎ# ㄮ┊›ぎ#
Loosen piston stud by using a torque spanner and
2.
(Optional)
Coat thread and contact surface of stud with
J0q# soxv# ru# J0q”ⓒᗲ# ᦪᜎ# 㑚⍦# ㋒›⼺# ›⻆ቲᜒ#
“Molycote-paste G-n plus or G-n”, and then tighten
58# Qp⓮# ⼶⸂ᗲ# ႖গẶᦿ㌻ⓒᗲ# ⸂ᔒ⑊⍦# ☆ᝓ㋲ၺ1#
the stud with a torque of 25 Nm to assemble to crown diagonally.
# # # # # # # # # # # # # # # # ›⻆ቲ⓮# ┊খ# ;716# pp# ┊㋮┊᠊# ㋒›⼺# ›⻆ቲᜒ# ╂Ṃ㋶# ᾮ# ┞⁋ၞၺ1#
If only the length of stud is less than 84.3 mm, reuse the piston stud.
M8
Fig.2 Cross section of piston complete +㋒›⼺# ၾ᠊ᅚ,#
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Page
H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
3/4
Section No.
Rev.
M31100
2E
G 61
›⻆ቲ⓮# ฮṂṆ⍦# ᡆᝂ⳪ぎ# ㄮ┊›ぎᜒ# ᦪᜊ੶# ㋒
71
81
3.
Coat thread of studs with molycote-paste and
›⼺# ›ⱺぎᜒ# ⸂ᔒ⑊⍦# ☆ᝓ㋲ၺ1# ⏖Ṻ⓮# ⌧᠊⍦ᅚ#
assemble piston skirt to crown. Before assembling
ᡆᝂ⳪ぎ# ㄮ┊›ぎᜒ# ᅚㆂ㋮⎂# ☆ᝓ㋲ၺ1#
washers, coat contact surface with molycote-paste.
ພぎᜒ# ႖গẶ# ᦿ㌻ⓒᗲ# 73# Qp⓮# ⼶⸂ᗲ# ☆┚# 㑚#
4. Tighten the nuts with a torque of 40 Nm, loosen
ၺ# ㈖੶# ›⻆ቲᜒ# 58# Qp⓮# ⼶⸂ᗲ# ၺ# ☆⎂Ẳ#
the nuts again, and tighten the stud bolt with a
㏫┎㋲ၺ1#
torque of 25 Nm for checking.
ພぎᜒ# 53Qp# গগ# ⩊㋲# 㑚# ⬪খ▗ⓒᗲ# 93㖡ᜒ#
5. Continue tighten the nuts with a torque of 20 Nm each by each and turn the nuts additional 60ȋ .
ც# ☆┎ၺ1#
Make sure that the nut is not rotated
ພぎဪ# ㍮# ⼶⸂# 78#Qpᜒ# ▗㋮⎂# ც# ┊
by application of test torque 45 Nm to tightening
ṗ# ☆⎂❖❖# ⋠⋚⌒# ㋿ၞၺ1# #
direction.
#
If the nuts can turn any more, replace
# # # # # # # # # # # # # # # ພぎখ# ☆ஞ┊ᔒᅚ# 㐢▚ⓚ# ㋮᠊/# Ṟᗲ⑊# ›
by new ones(stud & nut).
⻆ቲ⏖# ພぎᗲ# ૦⩊㋮₃⎺1#
㋒›⼺# ㋖# ᦥ# ⓮# ☆ᝓ#
Assembling of Piston Pin and Piston Rings
41
1.
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ☆ᝓ㋮ெ# ▚/# ㋒›⼺#
Coat the surface of piston pin and small end bush
㋖⓮# ㇲ᠊# ᦥ# ἢၾᬖ# ᬖ⍦# ෭㋲# ⎺┒ⓚ# ᦪᜎ# 㑚#
with clean lubricating oil before assembling piston
㋒›⼺# ㋖ⓚ# ᬖ# ἣⓒᗲ# ฒ③# ູဪၺ1#
and connecting rod shaft, and then mount piston pin into small end bush.
#
Make sure that the mark “E” on the
㋒›⼺# ṗᬖ⍦# ㇲᆲ# “H”# ⸂ᜒ# ᧆெ⮷ⓚ#
top of the piston should be positioned in exhaust
㌻㋮ᅚᗳ# ㋲# 㑚# ☆ᝓ㌊⌒# ㋿ၞၺ1# #
side.
#
51
㋒›⼺# ㋖# Ẳ⸊ᝓⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ┻
2.
Mount circlips for piston pin by means of plier.
⦿㋲ၺ1# ㊢ᔒ┊⍊# =# #
61
91.240
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ⸂ᖞ┎ⓚ# Ṃ㋮⎂#
Plier :
3.
㋒›⼺# ⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ㋒›⼺# #
4.
Mount piston rings into its grooves by means of the plier.
㏞⍦# ☆ᝓ㋲ၺ# ㊢ᔒ┊⍊# =# #
Lift up the piston together with connecting rod shaft by means of a crane.
ቺ⍊# ⏂ᝆၺ1# 71
91.240
91.250
Plier :
91.250
# # # # # # # # # # # # # # # ㋒›⼺# ⓮# ㋲⡓# ᠊⍦# Ṟਾ❚# “wrs”# ⸂ᜒ# ㏫┎㋲# 㑚/# ⸂খ# ㏞⓮# ⒚⡓ⓚ# ㌻㋮ᅚᗳ# ㌊⌒# ㋿ၞၺ1# # # # # # # # # # # # # # # গ# ㋒›⼺# ⓮# ෳၾ# ৃ┊# Ẳᗲ# 453㖡খ# ᆮ ᅚᗳ# ᧆ⯮⸺₃⎺1#
“Top” mark of piston rings should be assembled in upper side of groove. The end gap of each piston ring should be arranged in 120ȋ in relation to each other.
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H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
4/4
Section No.
Rev.
M31100
2E
G 81
4. Mount piston rings into its grooves by means of
㋒›⼺# ⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ㋒›⼺# #
the plier.
㏞⍦# ☆ᝓ㋲ၺ# ㊢ᔒ┊⍊# =# #
91.250
Plier :
91.250
#
“Top” mark of piston rings should be
# # # # # # # # # # # # # # ㋒›⼺# ⓮# ㋲⡓# ᠊⍦# Ṟਾ❚# “wrs”# ⸂ᜒ#
assembled in upper side of groove.
㏫┎㋲# 㑚/# ⸂খ# ㏞⓮# ⒚⡓ⓚ# ㌻㋮ᅚᗳ# ㌊⌒# ㋿ၞၺ1#
The end gap of each piston ring should
# # # # # # # # # # # # # # গ# ㋒›⼺# ⓮# ෳၾ# ৃ┊# Ẳᗲ# 453㖡খ# ᆮ
be arranged in 120ȋ in relation to each other.
ᅚᗳ# ᧆ⯮⸺₃⎺1# #
91
ၺ1#
:1
6.
எᝒ# 6# য┊# ㋒›⼺# ┊# ᠾᆮ⍞ဪ❖ᜒ# ㏫┎㋲
Inspect the piston rings for wear carefully as shown in fig. 3.
G09200
G09200
# # # # # # # # # # # # # # ㋒›⼺# ┊# ᠾ# ▲㋲⯮ᜒ# ⪞㋮⎖ਆฮ# ㋒
If piston rings exceed the wear limit
›⼺# ⍦# ᯚ▫ṗ▗┎# 㓷❧┊# ┞ၺ᠊/# Ṟ# ᬖ㈞ⓒᗲ# ૦⩊㋮₃
and/or if the piston has any abnormal mark, then
⎺1#
replace by new one.
7.
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎ# ┒⩊ᜒ# ⍪❚⍦# ╂㋲
Mount the piston together with connecting rod
ၺ1#
shaft into the engine.
+# # # # # M31000 # # # # # # # # # ⓮# “㋒›⼺# ⱺົ゛# ᗲቲᜒ# ⁺ᝆც#
(See “Mounting of a piston and connecting rod into
ᔒ┊ພ⍦# ☆ᝓ# ”# ᬖᬚⓚ# ⧎☆㋮₃⎺1,#
the cylinder liner” in
M31000 )
G G
Fig.3 The maximum vertical clearance of piston rings +㋒›⼺# ⓮# ⫲႖# ᾮ❗# ぞṞ,#
Marking on piston rings 1) 1st ring: GOE CK36 TOP GROOVE 1 2) 2nd ring: GOE or GOE TOP GROOVE 2 3) Oil scraper ring: GOE or GOE GROOVE 3
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Page
H21/32 Piston Assembly
Assembly Drawing & Part List
㋒›⼺ ⍊Ở᮪ᝂ
☆ᝓᅚ ᦥ ᬖ㈞ ᝂ›ぎ
1/1
Section No.
Rev.
A31100
3A
G 111
113
110
117
116
151 152 153
114 115 120
112
130
M32000
Part List Item No.
Description
Q’ty/Cyl.
Weight (kg)
Remarks / See Note
110
Piston complete
1
24.1
Item no. 111~117
111
Piston crown
1
6.72
112
Piston skirt
1
17.07
113
Stud bolt
2
0.08
114
Pressure washer
2
0.01
115
Hexagon nut
2
0.03
116
O-ring
1
117
Spring pin
1
120
Piston pin complete
1
9.5
130
Retaining ring
2
0.04
151
Compression ring – top
1
0.21
GOE CK36 TOP GROOVE 1
152
Compression ring – 2nd
1
0.17
GOE TOP GROOVE 2
153
Oil scraper ring
1
0.11
GOE GROOVE 3
Marking on piston rings G HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division
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H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
Section No.
Page
1/4 Rev.
M31100
3B
G #
#
㋒›⼺# ㋖# ᦥ# ⓮# ᬚ㌊#
Dismantling a Piston Pin and Piston Rings
41
1.
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ⍪❚# ᮪ᗳ⍦Ẳ# ᬚ㌊
Dismount the piston together with connecting rod
㋲ၺ1#
shaft from the engine.
+# # # # # #M31000 # # # # # # # # # ⓮G “㋒›⼺# ⱺົ゛# ᗲቲ⓮# ᬚ㌊# ”G ᬖ
OSee “Dismounting of a piston and connecting rod ”
ᬚⓚ# ⧎☆㋮₃⎺1,#
G G PG G G G G G PG inG G G G G GM31000
# 51
L0᪒ぎᜒ# ㋒›⼺# ⸂ᔒ⑊⍦# Ẻ⯮㋮੶/# ⸂ᖞ┎⍦# ႂ
2.
a crane.
⋚# ⏂ᝆၺ1# 61
Install I-bolt on the piston crown, and hook up onto
㋒›⼺# ⱺົ゛# ᗲቲ# Ṻ㊚ぎᜒ# ┧⍛႖⍦Ẳ# ቺ⍊⏂
3.
Lift up the piston together with connecting rod
ᝆ# 㑚/# ⱺົ゛# ᗲቲ# Ṻ㊚ぎ⓮# ▧㋿᠊ⓚ# ᠿ╂# ⻢┊᮪#
shaft from working stand, and slow down the joint
Ꭶဪ# ⒶṂ㋲# ☛ᛮ⒚⍦# ☆₂›ᖓਢ# ๊ᖺ# ༩ဪၺ1#
faces of connecting rod shaft on the wooden table or the likes carefully.
# # # # # # # # # # # # # # # # # #
Fig.1 Dismantling the circlips for piston pin +㋒›⼺# ㋖# Ẳ⸊ᝓ⓮# ᬚ㌊,#
# 71
எᝒ# 4# য┊# ㋒›⼺# ㋖# ⸊ᝓⓚ# ▚# ㊢ᔒ┊⍊ᜒ#
4.
as shown in fig. 1.
Ṃ㋮⎂# ᬚ㌊㋲ၺ1# ㊢ᔒ┊⍊# =# #
81
91.240
㋒›⼺ⓚ# ቺ੶# ┞ဪ# ṗ⍦Ẳ# ㋒›⼺# ㋖ⓚ# ႖ᦿ㌻ ⓒᗲ# ᳧⋚๎ၺ1#
Dismantle circlips for piston pin by means of plier
Plier :
5.
91.240
Take out the piston pin to the opposite side during lifting the piston.
#
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Page
H21/32 Piston Assembly
Maintenance Procedure
㋒›⼺ ⍊Ở᮪ᝂ
▫ᯚ▦ਖ ▞⦾
2/4
Section No.
Rev.
M31100
3B
G 91
㋒›⼺# ⓚ# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㋮⎂# ᬚ㌊㋲ၺ1# ㊢ᔒ┊⍊# =# #
6.
99.010
Dismantle piston rings by means of plier. Plier :
91.250 Be sure to use the plier for piston ring.
ቲ# ㋒›⼺# ▚# ㊢ᔒ┊⍊ᜒ# Ṃ㌊⌒#
Otherwise, piston rings may damage.
㋿ၞၺ1# எᖝ❖# ⋠ⓒ᠊# ㋒›⼺# ⍦# ἦṗ┊# ṳ# ᾮ# ┞⁋ၞ ၺ1#
:1
;1
⎆ἢ# ⚧# ྡྷ⍊# ᬯⓖ# Ⰺ# ⾊▗ᣒⓚ# ㋒›⼺# ㋒›⼺#
7.
# ㏞⍦Ẳ# ▲ਆ㋲# 㑚/# ᠾቶ# ᬖ㈞ቺⓚ# ෭┊# ၼ⋚๎
piston ring grooves, and clean all the parts
ၺ1# #
carefully.
㋒›⼺⍦# ᯚ▫ṗ▗┎# 㓶❧┊# ┞ဪ# ❖ᜒ# ┦Ỏ㔞# ਖṂ
8.
Inspect the piston for any abnormal marks carefully.
㋲ၺ1#
