EZ hy ie Piston & Connecting RodClockwise Rotation Engine | Coe t- o) 257 NE) Ra Lae Ped Piston & Connecting Rod No. 22 Outline 2201200 | 4/1 1. Piston & Piston ring The piston is thin solid/integral structure made of ductile cast iron. The ring grooves are laser hardened! quenched. For cooling of the upper part, the cocktail shaker system is adopted. ‘The piston is cooled by the lubricating oll supplied through the hole in the connecting rod. Piston rings consist of three rings. Two compression rings and one oil ring. Each ring has been chrome piated on the sliding surface. Fig. 22-01-1 Piston Structure & Piston Ring Types (Clockwise) Cooling Chamber RS oor race ~ 171 tapered Face TRL eovtes wan Cot pander ( 2. Connecting Rod & Bearing ‘The connecting rod is three-divided structure made of forged carbon steel. The piston can be drawn out by means of removing the upper rod bolts on the big end. The big end bearing is the split bearing composed of aluminum alloy and steel back metal. The small end bearing is the lead bronze bush with steel back metal.Clockwise Rotation Engine EY2G OPERATION MANUAL Piston & Connecting Rod No. Page 22 Overhaul of Piston & Piston Pin 22-02a-00 414 The frequency of piston drawing-out check varies according to the daily maintenance, especially the lubricat- ing oil control and load (overload and excessively low load). Therefore, the supervisor is required to decide the proper frequency. However, the initial overhaul and check should be performed at the time mentioned in Chapter 00-07. From then on, decide the subsequent check schedule according to the overhaul checking results, increase of blow-by and increase of lubricating oil consumption. When the lubricating oil consumption has become twice the initial value, it is necessary to overhaul and clean the piston, and replace the piston rings. 1, Disassembly 1) Disassembly Preparation Prepare the following special tools. No. ‘Special Tool Description Note @ _| Drawing out plate (protection ring) @ _| Liner retaining implement @ | Spacer @ _| Liner drawing-out upper implement @ Eyebolt Piston lifting 2) Removal of Protection Ring (1) Set the piston at the position of about 60 to 70° before the T.D.C. (2) Place the protection ring drawing out plate @ on the piston. Ls Place the plate so that its outer taper part faces toward the piston and do not allow it to make contact with the cylinder liner. (3) Mount the liner retaining implement @ and spacer @) and lock them with the cylinder head tightening nut (4) Tum the flywheel, and remove the protection ring Fig. 22-02-1 Removal of Protection Ring Oy. Head Tightening Nut Tapered Part assEY26 OPERATION MANUAL fae Piston & Connecting Rod Wo Fags 22 Overhaul of Piston & 22-02a-00 | 2i4 (5) Remove the disassembling tools and protection rings. (6) Eliminate the carbon from the upper part of cylinder liner. 3) Drawing out of Piston Sine the connecting rod is three-divided structure, the piston can be drawn out by removing the connecting rod bolts at upper part of big end Disassemble the piston and connecting rod according to the following sequence. (1) Remove the cylinder side covers of concerned cylinder from both operating side and non-operating side. (2) Tum the flywheel and set the crankpin at B.D.C. position so that the upper connecting rod bolts can be removed. (Select the position that socket wrench will not come in contact with the cylinder block.) (3) Confirm the set marks of connecting rod bolts prior to disassembly. (4) Loosen and remove the connecting rod bolts. (6) Screw the eyebolt into the piston so as to lift the piston. (6) Lift the piston slowly and pay attention to straight pins provided in the connecting rod and the big end housing (7) When the connecting rod comes off from straight pins of the big end housing, lit the piston completely to draw out it from the cylinder. (8) Check the damages on the mating surface of the big end housing and straight pins. Fig. 22:02-2 Drawing out of Piston (Clockwise) Eyebolt Straight Pin [anionClockwise Rotation Engine | Clockwise cn eae EY26 OPERATION MANUAL Pee Piston & Connecting Rod Overhaul of Piston & Piston Pin No. Page 314 22-02a-00 4) Removal of Piston Pin & Piston Ring (1) Remove the piston pin circlips with pliers. Note that the circlip springs out to cause you an injury if the tip of pliers comes out of the groove in course of removing the circlip. (2) Draw out the piston pin while holding the connecting rod. (3) Remove the piston ring with special tool /|\ CAUTION Wear gloves because the comers of rings will be sharp edged to cause you an injury after long term run- ning. a {caret not o wide the cut ofthe ing more than Bonn, Otherwise the ng may be broken 2. Checking & servicing Check the state of carbon adherent on the piston and the state of wear on the various parts. Refer to these checking results in deciding the subsequent check schedule. &S | Donot use the sandpaper to the surface of the piston skirt which has been provided with special coating. {_ (Carbon removing agent such as Unicon 146 or Neos is recommended to wash the piston.) (1) Check the contact surface of piston skirt. (2) Check the contact surface of piston pin holes, (3) Check the piston by Penetrate Test for cracks on top surface, ring grooves and inside. Fig. 22-023 Penetrate Test on Piston raClockwise Rotation Engine LD Et is MeL a eee Piston & Connecting Rod Overhaul of Piston & Piston No. Page la 22-02a-00 (4) Remove the piston cooling chamber cover, and check for adherent scale, (6) Measure the prescribed dimensions of piston and piston pin (6) Itis recommended to reptace the piston rings with new ones by considering the time to the next servicing. (7) Incase of replacing the piston, provide the same set mark on the new one as that on the previous one. 3. Installation of Piston (Clockwise) Install the piston in the sequence reverse to the drawing out procedure, paying attention to the following points, (1) Install the perforated piston cooling chamber cover on the opposite side of the piston set mark. Apply proper screw lock agent (Tokyo Three Bond Screw-Lock Not. or its equivalent) on the bolts before fiting a bolt. (2) Assemble the piston and connecting rod so that the piston set mark is at the plug side on the connecting rod small end. It means that the piston set mark and rod set mark locates at opposite side each other. (3) instal the piston pin circlip for its opening to face straight down direction. (4) Install the piston rings with their marked sides facing upward and their cuts shifted 120° from those of adjacent rings. (6) Install the oil ring with its coll joint position shifted 180° from its cut. (6) Install the piston and connecting rod in the way that the piston set mark is at operating side and the rod. set mark is at non-operating side. Fig. 2202-4 Installation of Piston (Clockwise) Fig, 22-02-6 Insert of Piston (Clockwise) Piston Set Mark Marking | Piston Inserting Guide 1 RN Cirlp Operting cover (Peroratea) cut Coll Joint Rod Set Mark (7) Set the crank pin to the B.D.C. position. (8) Apply clean engine oil on the piston, rings and cylinder liner. (8) Set the inserting guide on the cylinder liner, and install the piston. (Tap the piston with a resin hammer to drive the piston down.) aClockwise Rotation Engine EY26 OPERATION MANUAL Piston & Connecting Rod No. Page 22 Overhaul of Connecting Rod 22-03a-01 | 1/9 ‘The connecting rod is three-divided structure. Remove the upper rod bolts, and draw out the piston and con- necting rod first. After removing the piston and connecting rod, disassemble the big end housing by using the hydraulic jack 1. Removal of upper Rod Bolts Conceming the removal of upper rod bolts, itis written at the pages of "Drawing out of Piston". Please refer to the following section. (j22-02-1-3) Drawing out of Piston 2. Disassembly of Connecting Rod Big end Housing Disassemble the connecting rod big end housing according to the following procedure. 1) Disassembly Preparation (1) Prepare the following special tools. No. Tool Name Note 1 | Tool A 151695-92510 2 | Tool B 151695-92520 3. | Toolc 151695-92530 4 | Bott M20 x 1.5. L=30 5 | Eyebott 26610-08002 6 | Hydraulic Jack Refer to the Section 92 (2) Remove the cylinder side covers of concerned cylinder from both operating side and non-operating side. (3) Tum the flywheel to bring the big end housing to the non-operating side for disassembly. Concerning the turing of the flywheel, itis written at the pages of "Turning Device. Please refer to the following section, (Cjj22-02-1-3) Drawing out of Piston (4) Install the too! 8 on the windows of cylinder side cover at the operating side. (6) Insert the tool A from non-operating side window to operating side. (6) Fasten the set bolt to fix the tool A. (7) install the tool C and eyebolt to the big @nd housing.Le i) OPERATION MANUAL Piston & Connecting Rod No. Page 22 Overhaul of Connecting Rod 22-03a01 | 29 (8) Adjust the crankpin position so that big end housing is placed on the tool A. Fig. 22-03-1 Installation of the Tools (Clockwise) Tool Eyebolt Tool Toot A 2) Disassembly of Rod Bolt Nut Hydraulic jacks are used in disassembly and assembly of the rod bolt nuts. Loosen and tighten the nuts of one cylinder simultaneously. ‘Concerning the operation of the hydraulic jack, itis written at the pages of "Hydraulic Jack’. ] Please refer to the following section. | 122-02-1-3) Drawing out of Piston Fig, 22-03-2 Hydraulic Jack Coupler a Piston _- Body — Back-up Ring o-ring Hydraulic Jack a {Backup Ring ~ Spacer Tuming HandleEY26 OPERATION MANUAL Piston & Connecting Rod No. 22 Overhaul of Connecting Rod (1) Inspect that there are no flaw or dust at the threaded parts of the connecting rod. Fig. 22-03-3 Installation of Hydraulic Jack (Clockwise) Hydraulic Jack ‘Coupler (2) Insert a spacer to the outer periphery of a connecting rod bolt (at two spot). (8) Set the hydraulic jack on the rod bolt and screw in it until the spacer contact with big end and hydraulic Jack. (two bolts) (4) Loosen the hydraulic jack about 180° from the above contact condition (6) Connect a hydraulic pump to each hydraulic jack with rubber hoses. + Check that the hydraulic hoses are completely fitted in the couplers. + Make sure that the piston of hydraulic jack is flush with the end surface of the hydraulic jack body. (6) Operate the hydraulic pump to boost the hydraulic pressure to the specified pressure. Specified hydraulic pressure : 51 MPa| + Make sure that the surface of the hydraulic piston comes up 1 ~ 1.5mm upper from the body. (7) Insert the turning handle into a hole of nut through the hole of the spacer, then tum the nut counterclock- wise qa JN CAUTION | Ifyou cannot tum the nut withthe turing handle, slowly raise the hydraulic pressure and turn i | Do not raise the hydraulic pressure exceeding 60 MPa ‘on Sane aClockwise Rotation Engine EY2G OPERATION MANUAL OTS Piston & Connecting Rod No. Page 22 Overhaul of Connecting Rod Boron (8) Gradually open the relief valve of the hydraulic pump to lower the hydraulic pressure to 0 MPa. ZA\cAUTION a Make sure that the surface of the hydraulic piston is flush with the end surface of the hydraulic jack body. (Oil pressure is 0. ) (9) Disconnect the rubber hoses from the hydraulic jacks. (10) Remove the hydraulic jacks and spacers. (11) Remove the connecting rod bolt nuts. 3) Disassembly of Big end Housing ‘After removing the connecting rod bolt nut, remove the big end housing, ‘Tool A and B are used for disassembly (1) Place the big end housing on the tool A (2) Remove and take out the each half from each side window. Pay attention not to fall the crankpin metal. Pay attention not to damage the straight pin. (3) After the big end housing has been successfully taken out, remove the tools. (4) Install the cylinder side covers immediately after the removal to protect the entering of the impurity or for- ‘eign matters inside the cylinder block. 3. Checking 1) Piston Pin Metal (1) Check the crack or flaw on the piston pin metal (2) Check the contact and looseness in fit of piston pin metal. (3) Measure the inner diameter of piston pin metal. Ifthe measurement reaches the usage limit value or itis. considered that it will exceed the limit before next overhaul, replace the metal with the new one, Since the piston pin metal has been shrink fitted, remove it by hammering it out through an appropriate cushion piece or pressing it out 2) Connecting Rod (1) Check the flaw and yield on the mating surface with connecting rod and big end housing. /\cauTION Ifa water hammer has occurred of heavy burnout of the piston has been detected, measure the bend and indication of the connecting rod, and check the connecting rod by “Penetrate Test" for cracks. ye ery nyClockwise Rotation Engine EY26 OPERATION MANUAL fo Piston & Connecting Rod |INo. Page 22 i Overhaul of Connecting Rod eects 3) Big end Housing of Connecting Rod (1) Check the crack and wear on the serrated mating surface (2) Check the condition of damage of the mating surface and straight pins on the top. 4) Rod Bolt, Nut (1) Check the flaw and plucking on the bearing surface and threads of the bolt and nut. (2) If any flaw or plucking were found, correct it or replace the parts. (\caution (¥ prevent the rod bolts from being broken due to fatigue, replace them about every 20000 hours even if | ‘their appearance is normal. 5) Crankpin Metal (1) Check cracks, seizure and imbedded foreign matters on the sliding surface of each metal. (2) Check the contact on the rear and mating surface of each metal (3) Install the crankpin metals to the big end housing of the connecting rod, and tighten the rod bolt nuts with the hydraulic jack to the specified value. (4) Measure the inner diameter of the metals. ifthe measurement reaches the usage limit value or itis con- sidered that it will exceed the limit before next overhaul, replace the metals. (5) Measure the thickness of the upper and lower metals. If the difference between the dimensions A & C and the dimensions A & B is 0.4 mm or more, replace the metals. Fig. 22-03-4 Metal thickness measuring points ‘Approx. 40mm ‘thane aEY26 OPERATION MANUAL Piston & Connecting Rod Overhaul of Connecting Rod 22-03-01 6) Procedure of checking Crankpin Metal while Engine is in rest In the case of checking the crankpin metal without overhauling the cylinder head and piston while the engine is in rest, suspend the piston halfway as shown in the figure and proceed the checking, Fig, 22-03-5 Piston Suspending Fuel Valve Extracting Tool A Suspending Bott (Gerew in abt 15 mm) Piston Bi Z\\CAUTION (LD) 08-02 Operation of Tuming Device Sa ine aEY26 OPERATION MANUAL Piston & Connecting Rod Overhaul of Connecting Rod 4, Assembly of Connecting Rod Big end Housing 4) Installation of Crankpin Metal (1) In replacement of the metal, replace them by a pair of the upper and lower metals. (2) Note that the lower metal is provided with oil holes while the upper metal has no oll hole. Do not mistake cone for another. 2) Installation of Connecting Rod Big end Housing Install the connecting rod big end housing according to the procedures almost reverse to the disassembly pro- cedure. (1) Install the special tools on the cylinder block as described formerly at the section of "2-1) Disassembly Preparation”, (2) Clean the crankpin metal and big end housing (3) Tun the flywheel and set the crankpin position to the non-operating side. (4) Install the metal inthe big end housing without applying the oil on the back of the metal (6) Apply clean cil on the siding surface of the crankpin metal and set the big end housing on the tool B (6) Adjust the crankpin position so that its center coincident with the center of the housing, (7) Install the upper and lower big end housing to the crankpin and screw the connecting rod bolt nuts in the rod botts + Pay attention not to fall the crankpin meta + Before instaling the big end housing, check the straight pins on the top if they are normal (8) Set the hydraulic jack on the connecting rod bolts and connect the pump as the same procedure as described in the section "2-2) Disassembly of Rod Bold Nut" * Check that the hydraulic hoses are completely fitted in a coupler. (8) Operate the hydraulic pump to boost the hydraulic pressure to the specified pressure. (10) Turn the nut clockwise with the turning handle unti the bearing surface contact the connecting rod. (11) Gradually open the relief valve of the hydraulic pump to lower the pressure to OMPa. (12) Remove the hydraulic jack and hoses after checking that pressure is OMPa. (13) Remove tool A and B. 5. Assembly of Connecting Rod Before the installation of the connecting rod, it is necessary t necting rod. Therefore, refer to the following section. tall the piston to the small end of the con- [1}22-02- instalation of Pistonckwise Rotation Engine EY26 OPERATION MANUAL Piston & Connecting Rod No. 22 Overhaul of Connecting Rod Page 22-03a01 | 8/9 41) Installation of Connecting Rod (1) Set the crankpin position to the B.D.C. (Bottom Dead Center) position. (2) Set the mating surface of the big end to upper side. (This position is gained by its own weight.) (3) Install the piston according to the procedure described at section "22-02-3 Installation of Piston”. (4) Push down the piston and contact the mating surface of the connecting rod and big end housing, (6) Make sure that straight pins are correctly set. 2) Fastening of upper Rod bolt (angular method) ‘The connecting rod bolts are tightened by the angular method. In order to tighten the bolt correctly, marks indi- cating the specified clamping angle are stamped on the connecting rod (at two points A & B), In case of disassembling the connecting rod bolts or replacing them with a new ones, be sure to stamp the set mark again which has been stamped on each connecting rod bolt just before the shipment from our shop. It is because the tightening torque of the bolt varies as depended on accustoming of the bolt threaded part and bearing surfade. Fig. 22-03-6 Outlook of Rod Bolt Fig, 22-03-7 Tightening of Rod Bolt (Clockwise) (Angular method) Connecting rod 7" i Rod bolt. (Upper) Big end Housing Rod bolt (Lower) oy ae aClockwise Rotation Engine EY26 OPERATION MANUAL fora Piston & Connecting Rod No. Page 22 Overhaul of Connecting Rod puri lee When loosen the connecting rod bolts or replace them with new ones, it is necessary to stamp a new set mark ‘on the bolt to keep the correctness of the angular method. Stamp the set mark on the connecting rod over agi according to the following procedure. (1) Cut or grind off the set marks from the side of the bolt collar. (2) Check that there is no dust or flaw at the threaded part of the connecting rod bolts and on the connecting rod side. Clean them if found necessary. (3) Apply lubricating oil on the threaded part and protective grease on the bearing seat of the respective con- necting rod bolts. In case of replacing the connecting rod bolts or connecting rod, repeat tightening the bolts by the speci- fied clamping angle (90° ) and loosening them three of four times to make the bolts and the connecting rod accustomed each other (4) Using a torque wrench, tighten the bolts to the seating torque. Seating torque : 50 N -m (5) Stamp a set mark on the side of the bolt collar, aligning with the set mark at the point A on the connecting rod Fig. 22-03-8 Stamping of set mark ee (6) Tighten the bolts in 3 steps dividing the specified tightening angle in 3 steps. Tighten 4 bolts 30° as first step, and 60° as second step. Tighten 4 bolts 90° as last step. + Keep the deviation between the set mark of the bolt and the set mark B of the connecting rod in less than 2mm in the bolt tightening direction, ‘After replacing the connecting rod bolts or the connecting rod, stamp the same Cylinder No,, Bott No., etc. as those stamped on the previous ones. ‘ch nae Takin,th eth) eR Met cold | ER by - mie Parts List of Piston & Connecting Rod 22-52-00 | 12 SeeLe ty BEL eM LL cole erred BS ER bY - RR < ie Parts List of Piston & Connecting Rod 22-51a-00 | 22 > T fe | tent | oar | art he sacm | Partito [Gy | seers X__| 751692-22010 | EAKY CMP | PISTON ASS’ Y 6 aia 151692-22010 | EARY(D 212 PISTON, 0212 6s altar 151695-22390 | DS(EARY.7FFY | COVER PISTON 6 eal 151695-22340 | DS(EARY.7H7 9 _| COVER PISTON 6 a[a 133970-01780 | 5.347% D 24 | SPRING WASHER 2 6/4 26206-120202 | VK 12x 20 | BOT, 12K 20 2m é[ 4 2eait-i2012 | kARDIES 12x12 | SOREW WIOXI2 12 ult 151602-22140 | EARYY>F(NO. 1_| RING, PISTON 6 af 4 151605-22150 | CARY Y>F(NO. 2 | RING, PISTON 6 o[ 4 151695-22230 | #4 yy Faw | RING OL 6s to | 2 | x | 15166-22210 [arnu>zivs [RING O1LGR 6 ti | 2 [x | 151695-22220 | axwrsantee <1 | EXPANDER, COIL 6 wz] a 151695-22300 | EA KY ED CMP BLANKING COVER 6 13 | 2 | x | 151605-22310 | EARY ED PIN, PISTON 6 v4 | 2 | x | 151695-22320 | pI5 Kany PIPE, OIL STOP 6 | 1 22262-001100 | Kx CFF 110 [CIROLIP 110 12 x_ | 71695-23011 | axF4 27 Oy RYDE | ROD.ASS'Y, CONNECTING | fees wl] 151695-23081 | SAD F4>7c-y K | ROD, CONNECTING fs 7] 2 | x_| 15165-2071 | nosy HOUSING 6 ie | 2 | x | 151695-23080 [oy Kay 72 RE—> | ROD, LONG STROKE 6 19 | 2 | x | 1st6s5-23101 | xeuceabye> [wera Piston PIN, | 6 20 | 2 | x | 151695-23200 | ay FRE BOLT, CONNECTING ROD | 12 a | 2 | x | 11605-29210 | Fy RCA y FARR | NUT, CONNECTING ROD | 12 2 | 2 | x | 11695-29201 | oy FR ROO BOLT, CONN. ROD UPPER | 24 2 | 2 | x | 151695-29260 | s4ane> 12x20 | PIN, PARALLEL 12420 | 12 mld 151695-23910 | <7 Y>7(ayK. = | BEARING, ROD UPPER | 6 ~| 1 151695-23920 | <7 YVA(ayK.>5 | BEARING, ROD LOWER | 6 | 1 132654-29861 | 7 XIV(P L449 _ | VALVE ASSY, INJECTION | 6 7a 159629-23950 | AAD M20 SOREW, 20 6 a