PISTON Input Maintenance YANMAR SHIPSWEB

Input Maintenance | YANMAR SHIPSWEB 4/Aug/2022, 16,56
Maintenance Piston
Ship Nam FRONA 9585481
IMO
e
(Example
Engine M 6EY18ALW
Engine N 2873
)
Date
odel o. "01/Apr/
2019"
Running
Total Ru Hours
nning Ho since la
urs st overh
aul
Clean the piston

Clean the piston ring grooves and piston crown.
https://ye-shipsweb.yanmar.com/web/maintenance/input Page 1 of 19
#1
Inspection of Piston Cooling Chamber

Remove the cooling chamber cover and check carbon deposit inside.
If carbon deposits were found, implement chemical cleaning.
Nippon Yuka Kogyo Co. : HICARBON, Unisol KG
Kurita Water Industries : Kuripearl PF-1
#2
Check the cleaning the piston cooling chamber.
No.1 No.2 No.3 No.4 No.5 No.6

Check
Table
Inspecting Rear of the Piston

Check that the plug is installed in the piston pin housing.
#3
Check the cleaning the piston cooling chamber.

Check
Table
Piston Color Check (Dye Penetrant Test)

Apply Color Check to the piston crown, piston ring grooves and
piston rear side to know if or not any cracks exist.
#4
Result of color check for Piston

Check
Table
Clean the connecting rod.

Clean the serration and apply Color Check (dye penetrant test).
#5
Check the con. rod bolt.

Check that con. rod threads and seat face are not damaged.
Apply Color Check to the con. rod bolt.
#6
Result of color checking for Connecting rod bolt
Upper
Lower
Connecting rod Inspection

Check that female threads are not damaged or gouged.
* Do not use the con. rod when threads are damaged or gouged.
if used, con. rod can fracture due to the damaged or gouged threads.
#7
Lub oil hole of Con. Rod Inspection

Blow the air through the piston pin bearing LO hole to check that LO is supplied to th
e pin bearing.
#8
Check the con. rod large end at the cap-side.

Check that the large end cap-side seat face is not gouged.
If gouged, repair the area with oil stone, (remove burrs).
#9
Condition of female thread and seat face of large end cap.
Upper
Lower
Check that there blow air to lub oil hole

Check
Table
Check the piston pin bearing.

Check that there are no cracks in the piston pin bearing.
Measure the inner diameter of piston pin bearing.
#10
Result of color checking for piston pin bearing

Check
Table
Clean the serration

Clean the serration and check that serration is free from dust.
In particular, check that the con. rod bolt seat face of the large end cap is free fro
m dust.
#11
Clean the con. rod bolt and apply grease to the bolt.
When there is no problem with the con. rod bolt, apply system oil to the threads of bo
lt.
Apply PROTEC GREASE to the seat face of con. rod bolt.
If PROTEC GREASE is not available, apply the seizing inhibitor (molybdenum disufide)
#12
Assembly of Large End

Check that there left no foreign substance, lube oil or other fluids in bolt hole.
(Depending on bolt hole, it may not be pierced. Don't leave fluid in the hole.)
Align the ID mark on the large end cap with the ID mark of the con.rod.
Do not assemble the crankpin bearing still at this time.
#13
Check the ID mark on the large end cap bottom and the ID mark of the con. rod bolt to
be re-used.
Fasten the con.rod bolt manually until seated.
#14
Tightening of Large End

Tighten with 49N m
Mark Point A (temporary) on the bolt with a paint marker.
#15
Alternate tighten upper & lower bolts by turns in more than 3 stages, (40 ,80 ,120 ),
to cause con.rod bolt Point A aligned with con.rod Point B.
Do not tighten the bolt by more than 40 at a time
#16
Measurement of Large End Inner Diameter

After final tightening, measure the large end inner diameter.
Be sure to check that the value is within the allowable range.
#17
Result of large end inner diameter (within Limit)

Check
Table
Check cleaning of the piston.

Check that ID, (PUMP SIDE), marked on piston top and the piston cooling chamber cap fa
ce
to the same direction. In this case is 6EY18(A)L(W)
(Opposite installation can rarely happen,
so be sure to check the correct direction specified in the operation manual.)
#18
Check correct position of piston cooling chamber.

Check
Table
Assemble the connecting rod and the piston.

Align the piston top ID, (PUMP SIDE) and the ID mark on the con. rod.
The circlip end gap should face downward and the circlip edge outside.
#19
Check that ID mark of piston and ID mark of connecting rod is aligned.

Check
Table
Check that piston of Circlip.

Check
Table
Moving the piston & con.rod

Install piston rings before lifting the piston & con. rod.
Check that there left no dust, etc. on the cylinder liner.
Install the piston insertion tool and bring the piston above the engine.
Adjust the height for easy work and displace the piston ring end gaps.
#20
Checking the crank shaft surface

Clean the crankpin surface.
Remove dust, etc. completely. Check that the oil hole is pierced.
#21
Check that condition of crank pin and lub oil hole

Check
Table
Inserting piston to cylinder liner

Apply lube oil fully to piston rings, piston insertion guide and cylinder liner.
Lower the piston and when you felt resistance, knock on the piston top lightly with th
e handle of hammer.
Normally, the piston should descend when knocked on lightly.
If piston does not descend, piston ring installation may be faulty. In this case, extr
act the piston once.
#22
Checking the crank pin bearing

Descend piston gradually to the position where crankpin bearing can be installed
to con. rod through crankcase door.
Make sure to align pawl of crank pin bearing to pawl hole of the large end.
Do not hit the con.rod to crank shaft.
Install the crankpin bearing to the con. rod. (Do not apply lube oil to the rear face
of crankpin bearing.)
Apply lube oil fully to the crankpin bearing and crankshaft.
#23
Check that installation of crank pin bearing.

Check
Table
Draw the big end of con.rod to the crank shaft

Check that the crankpin is free from dust, etc.
Descend the piston and fit the con. rod slowly to the crankshaft.
Never descend the piston quickly.
#24
Large End Assembly

Check the ID mark on the large end cap bottom and ID mark on the con. rod bolt.
Apply PROTEC GREASE to the seat and lube oil to the threads of con. rod bolt.
Tighten it manually until seated.
#25
Checking the mark of rod bolt & cap
Upper
Lower
Tighten the Large end

Tighten upper & lower con.rod bolts by turns in more than 3 stages (40˚,80˚,120˚),
for aligning con.rod bolt Point A with con.rod Point B.
* Do not tighten the bolt by more than 40˚at a time.
#26
Checking the tightening of con rod bolt.
Upper
Lower
Re-checking Large End Tightening

Re-check that con. rod bolt Point A aligns with Point B at the con. rod side.
#27
Checking the match mark for connecting rod and connecting rod bolt.
Upper
Lower
Check of Large End Side Motion

After checking that ID marks are aligned, check side motion of each cylinder.
Check that con. rod moves left & right lightly.
(You may screw in the minus screw driver between the crank arm and con. rod.)
When there is no side motion, there is problem with piston pin side or large end side.
In this case, re-checking is necessary.
#28
Result of checking the side motion

Check
Table
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Input Maintenance | YANMAR SHIPSWEB 4/Aug/2022, 16,56

Clean the piston

Inspection of Piston Cooling Chamber

Check the cleaning the piston cooling chamber.

No.1 No.2 No.3 No.4 No.5 No.6

Inspecting Rear of the Piston

Check the cleaning the piston cooling chamber.

No.1 No.2 No.3 No.4 No.5 No.6

Piston Color Check (Dye Penetrant Test)

Result of color check for Piston

No.1 No.2 No.3 No.4 No.5 No.6

Clean the connecting rod.

Check the con. rod bolt.

Result of color checking for Connecting rod bolt

No.1 No.2 No.3 No.4 No.5 No.6

Connecting rod Inspection

Lub oil hole of Con. Rod Inspection

Check the con. rod large end at the cap-side.

Condition of female thread and seat face of large end cap.

No.1 No.2 No.3 No.4 No.5 No.6

Check that there blow air to lub oil hole

No.1 No.2 No.3 No.4 No.5 No.6

Check the piston pin bearing.

Result of color checking for piston pin bearing

No.1 No.2 No.3 No.4 No.5 No.6

Clean the serration

Assembly of Large End

Tightening of Large End

Measurement of Large End Inner Diameter

Result of large end inner diameter (within Limit)

No.1 No.2 No.3 No.4 No.5 No.6

Check cleaning of the piston.

Check correct position of piston cooling chamber.

No.1 No.2 No.3 No.4 No.5 No.6

Assemble the connecting rod and the piston.

Check that ID mark of piston and ID mark of connecting rod is aligned.

No.1 No.2 No.3 No.4 No.5 No.6

Check that piston of Circlip.

No.1 No.2 No.3 No.4 No.5 No.6

Moving the piston & con.rod

Checking the crank shaft surface

Check that condition of crank pin and lub oil hole

No.1 No.2 No.3 No.4 No.5 No.6

Inserting piston to cylinder liner

Checking the crank pin bearing

Check that installation of crank pin bearing.

No.1 No.2 No.3 No.4 No.5 No.6

Draw the big end of con.rod to the crank shaft

Large End Assembly

Checking the mark of rod bolt & cap

No.1 No.2 No.3 No.4 No.5 No.6

Tighten the Large end

* Do not tighten the bolt by more than 40˚at a time.

Checking the tightening of con rod bolt.

No.1 No.2 No.3 No.4 No.5 No.6

Re-checking Large End Tightening

No.1 No.2 No.3 No.4 No.5 No.6

Check of Large End Side Motion