Operation Manual

Job Card No.:
Engine:
Filing No.:
Piston
0178-07-297 5843
● When the first piston inspection becomes due
according to the maintenance schedule, the con-
dition of pistons and piston rings is checked by
inspecting the cylinder liner working surfaces
from the combustion chamber using an endos-
cope (Job Card 01.05.04), or from the crankcase.
If the cylinder heads have been removed, inspect
as per Job Card 01.08.01.
● Thereafter draw one piston per cylinder bank. Remove that piston whrer the liner working surface appears
to be in the worst shape (Job Card 02.09.01), in order to prevent faulty assesment of the piston status..
● Remove connecting rod as per Job Card 02.12.01.
● Clean cooling spaces, supply and discharge bores in the piston crown and body.
● Carefully remove oil carbon disposits in the piston using a scraper. If the disposit layer is > 3 mm, check
piston for consequential damage.
● Measure the combustion chamber contour of the piston. The centre of the piston in the case of motors
with a compreesion ratio of
e = 11.7 mm it must stand back by 0.8 mm - 1.1 mm
e = 13.0 mm it must stand back by 2.3 mm - 2.6 mm
● If
- the working surfaces of all cylinder liners are free from bright spots, scores and other defects, see also
job 03.02.0,
- the drawn pistons are in perfect condition,
(in the case of engines, running on HFO, it must be checked whether there are oil carbon deposits in
the piston cooling space. For this purpose introduce a screwdriver through the cooling oil discharge
bore and check whether there exist any deposits. If a deposit layer is perceivable, i.e. exceeding ca. 0,5
mm, all pistons must be inspected and reconditioned as per Job Card 02.10.04.),
- erosions of max. 1 mm in the area of the injection nozzle jets,
- all piston rings are free from burned spots (brown/blue),
- all piston rings are moving freely and not excessively worn, i.e.:
- Running layers still fully intact and without signs of crumbling, no sharp edges,
- Chromium plating on the rectangular ring still fully in tact and without cracks,
- No running edge on the chamfered oil control ring exceeding 1 mm.
the inspection of the remaining pistons may be postponed to the next inspection specified in the
Maintenance Schedule. At that time a second inspection is carried out in the way as described above.
If the findings are once again in order, servicing of all pistons may be postponed by another inspection
interval.
● Should it become obvious during one of these inspections that the drawn piston shows any defects, all
other pistons must be removed and serviced. If deviating values are measured, do not re-use piston! It is
necessary to consult DEUTZ Service.
● For grater safety, inspect all other liners from the crankcase.
The engine running hours up to the time when all pistons must be removed for the first time are
considered as regular servicing interval for pistons in accordance with "S cheduled Maintenance".
Enter the servicing interval in the Maintenance Schedule.
© 0693
02.10.01 Page 1 of 3
S/BVM 628
Inspection
The piston servicing intervals with regard to "Sche-
duled Maintenance" are very different, depending on
engine application and loading. The following proce-
dure has been established so that efficient servicing
intervals can be determined.
Job:
Tools:
- Standard tools
Job Cards:
- 01.05.04
- 01.08.01
- 02.04.01
- 02.09.01
- 02.10.02
- 02.10.04
- 02.12.01
- 03.02.01
- 06.02.01