Piston Ring settings

Piston Ring settings

Step 1: Cleaning the pistons

Clean the pistons thoroughly first of all and remove all traces of carbon from the ring grooves. Remove the carbon from the oil return bores with a twist drill and tap wrench. Clean the grooves without damaging the groove sides in the process. Replace cracked or sunken and worn pistons.

Step 2: Checking the piston ring grooves

If between a parallel sided compression ring and the associated groove flank a distance of 0.12 mm or more is measured, the piston is excessively worn and must be replaced.

Groove clearance

Measurement of the piston ring grooves with a feeler gauge. KS art. no. 50 009 824

Usability of the pistons	Groove clearance (mm)
Pistons can be used without concern	0,05 – 0,10
Increased caution is required	0,11 – 0,12
A new piston must be used!	> 0,12

Top ring reversal bore wear

Step 3: Checking the cylinder wear and tear

If the cylinder wear is higher than 0.1 mm for Otto engines and 0.15 mm for Diesel engines, the cylinder must also be replaced (top ring reversal bore wear).

Step 4: Cleaning the cylinders

Remove carbon residues at upper unused area of the cylinder liner.

Checking with KS calliper with dial gauge, accuracy 0.01 mm KS art. no. 50 009 814

Step 5: Checking the ring set components

When replacing the piston rings, we always recommend replacing a complete set. The ring height is checked with a calliper. A comparison with our catalogue data is recommended.

The diameter can be checked with a measuring ring or reworked cylinder; the joint clearance based on a subjective assessment or with a feeler gauge. When checking the ring diameter in worn cylinders/cylinder liners, note that the joint clearance can assume larger values.

Chrome plated piston rings must not be installed in chrome plated cylinder liners.

Piston ring pliers
KS art. no. 50 009 815 for ø 50–110 mm
KS art. no. 50 009 829 for ø 110–160 mm

Step 6: Installing the piston rings

Insert the piston rings into the respective piston ring groove with the correct fitting tool.
Excessive spreading of the piston rings during mounting is to be avoided; this causes permanent deformations and affects the piston ring's performance.

The “TOP” marking must point to the piston crown, so that the scraping effect is pointing to the skirt end of the piston.

Special:
Installation of steel rail spring washers

1. The expander spring is fitted into the groove.

Steel rail oil ring - correct

Steel rail oil ring - wrong

Note:
With three-digit steel rail spring washers, it can happen that the expander spring overlaps on the joint ends. For this reason, always control the position of expander feathers before installing the pistons.

2. The bottom fin is inserted by 120° joint twist.

Step 7: Function test / Twisting the piston rings

Once the piston rings are installed, it must be ensured that they can move freely. Twist the joint ends of the piston rings by 120° each on the piston.

Note:
Pistons for two-stroke engines with piston rings which are secured against twisting must not be twisted when inserted into the cylinders. In this process, the locking pin can move below the piston ring sprung outwards in the area of a cylinder window and break this off at the opposite window edge.

Step 8: Inserting the piston into the cylinder liner

Sufficiently oil piston rings and pistons and install with a closing piston ring clamp or a conical assembly sleeve to prevent the piston rings from being damaged.

Kolbenschmidt art. no.	Name
50 009 816	Piston ring scuff band for ø 57 – 125 mm
50 009 828	Piston ring scuff band for ø 90 – 175 mm
50 009 913	Piston ring assembly kit set

Piston ring assembly kit set

Piston Ring Installation

Hi Guys welcome to my Deisel engine workshop soo I share u piston ring installation and all abouted ..

RING INSTALLATION

All piston ring sets contain information relative to the proper installation of the rings packaged in the set.

Three Piece Flex Vent

First, place the spacer in the grove. Then spiral the first rail into the groove below the spacer followed by the remaining rail into the groove above the spacer.

One & Two Piece Oil Rings

Using a proper ring installation tool, open the oil ring just enough to allow the ring to go over the top diameter of the piston. Work the opened ring down from the top of the piston to the oil groove. Place the ring squarely into the piston groove, taking care to keep it flat. Release the tension of the ring installer tool.

When using a two piece oil, install the hump style spring in the groove then follow the above instructions.

Compression Rings

Although in many cases most compression rings appear similar to the mechanic installing them, there are, however, many subtle design changes which dictate how the ring is correctly installed.

Not only must the ring be installed with the proper side toward the top of the piston, but it is also imperative that the ring be installed in the proper groove.

Rings installed in the wrong groove or wrong side up can lead to excessive oil pumping, excessive blow-by, and in some cases completely dry up the bore, causing ring and cylinder scuffing as well as accelerated wear. Any of these problems, of course, constitute a failure as far as an engine overhaul or rebuild is concerned.

Lay the rings out in groups of tops ring and 2nd rings on the bench.
Check for TOP marks (DOT or lasor marks).

With the oil control rings loaded on the piston, using a  proper  ring installation tool,  open the second groove rings with the top mark up, just enough to allow the ring to go over the top diameter of the piston. Work the opened ring down from the top of the piston to the second groove, place the ring squarely into the piston groove taking care to keep it flat, release the tension of the ring installer tool (ring is now installed).

Repeat this same process with the Top groove rings.
(Compression rings must never be spiraled on the piston.)

Final Steps

Once the piston rings are on the piston, “stagger” the end gaps. It is important that the ring end gaps are not lined up.  This prevents oil flow past the rings.

Rings installed in the wrong grooves or the wrong side up can lead to excessive oil consumption and blow-by and possible scuffing of the cylinders.
These problems can cause engine failure.

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GB40 Gearbox

GB40 Gearbox kese fitting karte hai step by step all about
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GB60 Gear Box

GB60 Gearbox
 60 gearbox kese fitting karte hai.

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Bosch Edc Pump

Ultra Bus BS4

STAR BUS ULTRA BS4

• Chassis PlatformLPO 10.2 T/ 52 BS IV Diesel
• Engine3l NG DICR BS4 Engine
• Engine Power102 kW @ 3000 r/min
• Engine Torque360 Nm @ 1400-2000 r/min
• Clutch Diameter330 mm
• GearboxG-550; 6-speed with overdrive
• BrakesAir Brakes
• SuspensionParabolic leaf spring at front & rear
• Anti-roll barYes
• SteeringPower
• Battery24 V, 150 Ah
• Tyres235/75 R - 17.5
• Fuel Tank Capacity (litres)160 l
• Turning Circle Diameter (M)17.7 m
• Max. GVW (kg)10200 kg

BODY

• Seating Capacity & Layout46 Hi-back + 1D,3x2
• StructureGalvanized tubular structure
• AC MakeSpheros CC 225
• Emergency Exits1 breakable rear glass with hammer; 1 emergency window behind driver; door at rear RH side
• Side WindowsPasted glasses with 2 nos. ventilation windows at each side
• Fire Extinguisher2 nos. of 6 kg capacity

OVERALL DIMENSIONS

• Wheelbase5200 mm
• Length10120 mm
• Rear Overhang3120 mm
• Front Overhang1800 mm
• Max. Width2550 mm