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2018

Engine Bearings
DE EN FR
Lagerbauart Bearing design Type de coussinet

AS Anlaufscheiben Thrust washers Rondelles de guidage


BU diverse Buchsen Various bushes Diverses bagues
HL Hauptlager Main bearings Coussinets principaux
KH-B Kipphebelbuchsen Rocker arm bushes Bagues de culbuteur
NW-L Nockenwellenlager Camshaft bearings Coussinets d’arbre à cames
PASS-L Passlager Flanged bearings Coussinets de butée
PL Pleuellager Conrod bearings Coussinets de bielle
PL-B Pleuelbuchsen Conrod bushes Bagues de bielle
PL-L Pleuellager für K
­ ompressoren Conrod bearings for compressors Coussinets de bielle pour compresseurs
Werkstoff Material Matériau

A Aluminiumlegierung Aluminium alloy Alliage d’aluminium


B Massive ­Bleibronze­legierung Solid lead bronze alloy Alliage plomb-bronze massif
St/A Stahlrücken mit ­auf­plattierter Steel back plated with Al alloy Dos d’acier avec alliage Al plaqué
Al-Legierung
St/A/B Stahlrücken mit aufplattierter Steel back with plated Al alloy and galvanic Dos en acier avec alliage Al doublé et
Al-Legierung und Bonder-Gleitschicht bearing surface layer couche bondérisée

St/A/H Stahl- Aluminium-Legierung Steel aluminium alloy Alliage acier-aluminium


(hochbelastbar) (heavy duty) (haute résistance)
St/A/P Stahlrücken mit aufplattierter Al-Legie- Steel back plated with Al alloy and poly- Dos d’acier avec alliage Al plaqué et
rung und Polymer-Gleitschicht mer sliding layer couche de glissement polymer

St/B Stahlrücken mit aufgesinter­ter Steel back with sintered lead Dos en acier en alliage de bronze fritté
Bleibronze-Legierung bronze alloy
St/B/G Stahlrücken mit auf­gesinter­ter oder auf­ Steel back with sintered or cast lead Dos d’acier avec alliage plomb-bronze
gegossener Bleibronze-­Legierung und bronze alloy and galvanic sliding layer fritté ou coulé et couche de glissement
galvanischer Gleitschicht mit Cu 3 % with Cu 3 % galvanisée avec Cu 3 %

St/B/G1 Stahlrücken mit aufgesin­ter­ter oder auf­ Steel back with sintered or cast-on lead- Dos en acier avec Plomb-Bronze fritté
gegossener Bleibronze-Legierung und bronze alloy and galvanic bearing surface ou coulé et avec couche de glissement
galvanischer Gleitschicht mit Cu 6 % layer with 6 % Cu galvanisée à 6 % de Cu
St/B/G F Stahlrücken mit aufgesinterter oder auf­ Steel back with sintered or cast-on bronze Dos en acier avec alliage Bronze coulé
gegossener Bronze und galvanischer alloy and galvanic bearing surface layer ou aggloméré par frittage et couche
Gleitschicht (bleifrei) (unleaded) galvanisée (sans plomb)

St/B/S Stahlrücken mit aufgegosse­ner Steel back with cast lead bronze alloy and Dos d’acier avec alliage plomb-bronze
Bleibronze-­Legierung und gesputterter sputtered sliding layer coulé et couche de glissement sputter
Gleitschicht
St/B/S F Stahlrücken mit aufgesinterter Bronze- Steel back with sintered bronze alloy Dos en acier avec couche en alliage de
Legierung „SPUTTER“ (bleifrei) „SPUTTER“ (unleaded) bronze fritté „SPUTTER“ (sans plomb)

St/W Stahlrücken mit aufgegossener Steel back with cast-on white metal alloy Dos en acier revêtu d’un alliage de métal
Weißmetall-­Legierung blanc coulé
Motorart Engine type Type de moteur

A Aufgeladen Supercharged Suralimenté


BI Saugrohreinspritzung manifold injection injection par conduite d‘aspiration
C Vergaser carburettor carburateur
CR Common Rail Common Rail Common Rail
DI Direkteinspritzung direct injection injection directe
K Kompressor Compressor Compresseur
LA Aufgeladen mit Ladeluftkühlung Supercharged with charge air cooling Suralimenté avec refroidissement d’air de
suralimentation
PD Pumpe-Düse Einspritzanlage Pump-nozzle-injection Pompe-trous-injection
Kraftstoffart Type of fuel Type de carburant

AB Flexfuel Flexfuel Flexfuel


AL Alkohol Alcohol Alcool
B Benzin Petrol Essence
D Diesel Diesel Gazole
G Gas Gas Gaz
GF Flüssiggas (Propan/Butan) Liquid gas (propane/butane) Gaz liquide (propane/butane)
ES RU AR
Tipo de cojinete Конструкция подшипника

AS Arandelas de tope Регулировочные шайбы


BU Diversos casquillos Различные гильзы
HL Cojinete principal Коренные подшипники
KH-B Bujes de balancín Втулки коромысла
NW-L Cojinetes del eje de levas Подшипники распределительного вала
PASS-L Cojinete de empuje Упорные подшипники
PL Cojinetes de la biela Шатунные подшипники
PL-B Casquillos de biela Втулки нижних головок шатунов
PL-L Cojinetes de la biela para compresores Шатунные подшипники для компрессоров
Material Материал

A Aleación de aluminio Алюминиевый сплав


B Aleación masiva de bronce y plomo Прочный сплав свинцовистой бронзы
St/A Dorsal de acero revestido con aleación de Стальная спинка с нанесенным
aluminio алюминиевым сплавом
St/A/B Dorsal de acero plaqueado con aleación de Стальная спинка с нанесённым
aluminnio y capa deslizante bonderizada плакированием алюминиевым сплавом
и нанесённым бондеризацией слоем
скольжения
St/A/H Aleación de acero-aluminio Сплав стали и алюминия
(altamente resistente) (высокопрочный)
St/A/P Dorsal de acero revestido con aleación de alu- Стальная спинка с нанесенным
minio y una capa de deslizamiento polymer алюминиевым сплавом и полимерным
скользящим слоем
St/B Dorsal de acero con aleación bronce-plomo Стальная спинка с нанесённым спечением
sinterizada сплавом свинцовистой бронзы
St/B/G Dorsal de acero con aleación sinterizada o Стальная спинка со спеченным или
fundida de bronce y plomo y una capa de des- литым сплавом свинцовистой бронзы
lizamiento galvanizada con el 3 % de cobre и гальваническим скользящим слоем с
содержанием Cu 3 %
St/B/G1 Dorsal de acero resestido por sinterizado o Стальная спинка с нанесённым спечением
colada de aleación bronce-plomo y capa de или залитым сплавом свинцовистой бронзы
deslizamiento galvánica con un 6 % Cu и гальваническим слоем скольжения 6 % Cu
St/B/G F Dorsal de acero revestido por sinterizado Стальная спинка с нанесённой спечением
o colada de aleación bronce y capa de или залитой свинцовистой бронзой и гальв.
deslizamiento galvánica (sin plomo) слоем скольжения (неэтилированный)

St/B/S Dorsal de acero con aleación fundida Стальная спинка с литым сплавом
de bronce y plomo y una capa de deslizamiento свинцовистой бронзы и напыленным
„Sputter“ скользящим слоем
St/B/S F Dorsal de acero con aleación bronce sinterizada Стальная спинка с нанесённым спечением
„SPUTTER“ (sin plomo) сплавом свинцовистой бронзы „SPUTTER“
(неэтилированный)
St/W Dorsal de acero revestido por colada de Стальная спинка с залитым оловянистым
aleación de metal blanco антифрикционным сплавом
Tipo de motor Тип двигателя

A Sobrealimentado С наддувом
BI inyección en el tubo de aspiración впрыскивание во впускную трубу
C carburador карбюратор
CR Common Rail oбщий топливопровод высокого давления
DI inyección directa непосредственное впрыскивание
K Compresor Компрессор
LA Sobrealimentado con enfriamiento С наддувом и охлаждением
del aire de admisión наддувочного воздуха
PD Bomba-tombera-inyección Насос-сопло-устройство впрыска
Tipo de combustible Вид горючего

AB Flexfuel Flexfuel
AL Alcohol Спирт
B Gasolina Бензин
D Diésel Дизель
G Gas Газ
GF Gas licuado (propano/butano) Сжиженный газ (пропан/бутан)
Engine bearings with
polymer coating

Reduced friction, increased strength and wear resistance


thanks to the new combination of metal and polymer.
Various technologies are being developed to reduce
CO2 emissions, such as start-stop or coasting operation.
These types of engine operation require engine bearings with
greater wear resistance. This is why the engine bearings have
an additional polymer sliding layer. The bearing metal and
polymer layer thus satisfy the conflicting requirements such
as adaptability, wear resistance and simultaneous resilience.
Grundlagen

DEUTSCH
2018
Gleitlager

ENGLISH
Engine bearings
Coussinets
Cojinetes de deslizamiento
Подшипники скольжения

FRANÇAIS
Index Page

DE | Grundlagen 2
Hinweise zur Benutzung des Katalogs 8

EN | Basic information 14
Instructions for using the catalogue 20

FR | Généralités 26

ESPAÑOL
Précisions sur l’utilisation du catalogue 32

ES | Fundamentos 38
Indicaciones para la utilización del catálogo 44

RU | Основы 50
Примечания по пользованию каталогом 56

AR | 71
65
РУССКИЙ

Disclaimer
Namen, Beschreibungen, Nummern von Motoren, Les noms, les descriptions, les numéros de moteurs, les Названия, описания и номера двигателей,
Fahrzeugen, Produkten, Herstellern etc. sind nur zu véhicules, les produits, les constructeurs, etc., ne sont транспортных средств, продуктов, изготовителей и т. п.
Vergleichszwecken aufgeführt. donnés qu’à des fins de comparaison. приводятся только для сравнения.
Die im Katalog enthaltenen Teile sind Ersatzteile für die Les articles mentionnés dans le catalogue sont des pièces Содержащиеся в каталоге части представляют собой
aufgeführten Applikationen. de rechange destinées aux applications stipulées. запасные части для приведенных продуктов.

Names, descriptions and numbers of engines, vehicles, Los nombres, las designaciones y los números de motores, ‫أسماء وشروح وأرقام المحركات والسيارات والمنتجات والشركات المنتجة وغيرها‬
products, manufacturers, etc. are mentioned solely for the vehículos, productos o de fabricantes, etc., se indican .‫مذكورة فقط بهدف المقارنة‬
purpose of comparison. sólo a modo de comparación. .‫واألجزاء المذكورة في الكتالوج عبارة عن قطع غيار للتطبيقات المذكورة‬
The parts contained in the catalogue are spare parts for Las piezas incluidas en el catálogo son repuestos para las
the applications listed. aplicaciones indicadas.
Grundlagen
DEUTSCH

Wichtige Hinweise dass das Produkt für den beabsichtigten nisses. Derartige Beanstandungen müssen
Die Angaben in diesem Katalog sind Verwendungszweck geeignet ist. Um dies uns binnen einer Frist von 30 Tagen nach
sorgfältig bearbeitet, aber unverbindlich. sicherzustellen, ist in jedem Fall vor Einbau Auftreten des Schadens schriftlich mitge-
Für die Richtigkeit dieser Angaben über- der fachkundige Rat des Herstellers oder teilt werden.
nehmen wir keine Gewähr. Insbesondere dessen autorisierter Vertragswerkstatt Die Verjährungsfrist für Mängelan­sprüche
können Änderungen der Ausrüstung durch einzuholen. beträgt 12 Monate, gerechnet ab Abliefe-
die Fahrzeug- oder Motorenhersteller bzw. Die im Katalog angebotenen Teile sind rung der Sache.
Änderungen der Bezeichnungen nicht nicht für den Einsatz in Luftfahrzeugen Mängelansprüche erlöschen, wenn der
ausgeschlossen werden. Informationen bestimmt. Bei der Verwendung in Marine- Liefergegenstand von fremder Seite oder
über eventuelle Fehler im Katalog sind Motoren und Stationär-Motoren ist darauf durch Einbau von Teilen fremder Herkunft
uns stets willkommen und werden in den zu achten, dass bei gleicher Motorbezeich- verändert wird, es sei denn, dass der Man-
zukünftigen Ausgaben korrigiert. Namen, nung unterschiedliche Motorenteile (z. B. gel nicht in ursächlichem Zusammenhang
Beschreibungen und Nummern­angaben Kolben) zum Einsatz kommen können. mit der Veränderung steht. Sie erlöschen
von Fahrzeugen oder Herstellern u. ä. sind weiter, wenn Handhabung und Ein­bau nach
nur zu Vergleichszwecken auf­geführt. Wir Nachdruck, Nachahmung und Vervielfäl­ geltender Vorschrift nicht befolgt wurde.
be­halten uns vor, Produktspezifikationen, tigung, auch auszugsweise, sind nur mit Normaler Verschleiß und Beschädigung
Werkstoffe und Aussehen unserer Produkte unserer schriftlichen Genehmigung und mit durch unsachgemäße Behandlung sind von
jederzeit zu ändern. Quellenangabe gestattet. Mit Erscheinen der Gewährleistung ausgeschlossen.
dieses Katalogs verlieren frühere Ausgaben
Die Funktion und der im Katalog angege- ihre Gültigkeit.
bene Verwendungszweck bleiben davon Umweltmanagement
unberührt. Abbildungen, Schemazeich- Änderungen und Irrtümer vorbehalten. Verantwortungsvoller Umgang mit
nungen und andere Angaben dienen der ­Ressourcen, der Schutz unserer Umwelt
Erläuterung und Darstellung und können und die Einhaltung aller relevanten
nicht als Grundlage für Einbau, Lieferum- Qualitätsmanagement gesetzlichen Verpflichtungen sind für eine
fang und Konstruktion verwendet werden. Zum Zeichen, dass unser Qualitäts­mana­ langfristige Zusammenarbeit mit allen
Angaben über Original-Ersatzteilnummern gement die Anfor­der­ungen der einschlägi­ unseren Partnern von großer Bedeutung.
der Fahrzeug- und Motorenhersteller gen internationalen Normen erfüllt, sind Dies waren die Gründe, die uns motivier-
dienen nur zu Vergleichszwecken. Sie sind wir nach ISO 9001 zertifiziert. ten, die Anforderungsnorm für Umwelt­
keine Herkunftsbezeichnungen und dürfen managementsysteme ISO 14001 zu
gegenüber Dritten nicht verwendet werden. Sollte trotz der laufend durchgeführ­ten erfüllen und unsere Organisation zertifizie-
Für die Anwendung der Vergleichslisten Kontrollen während des Produk­tions­ ren zu lassen.
können wir insbesondere wegen möglicher prozesses und der gründlichen Endkon-
Änderungen und/oder Maßdifferenzen trolle ein Material- oder Ferti­gungsfehler
der einzelnen Hersteller keine Haftung auftreten, übernehmen wir selbstver-
übernehmen. ständlich innerhalb der Verjährungsfrist
CERTIFICATE
Zudem wird keine Haftung übernom- entweder die Instand­setzung des Motors This is to certify that

Certificate
men für die Richtigkeit der Daten und oder den Ersatz des beanstandeten Erzeug-
MS Motorservice International GmbH
Wilhelm-Maybach-Straße 14-18
74196 Neuenstadt
Germany
Standard ISO 9001:2008
Certificate Registr. No. 01 100 4255
has implemented and maintains an Environmental Management System.

Certificate Holder:

Scope:
Assembling and trading of Engine Parts for the Aftermarket MS Motorservice International GmbH
Wilhelm-Maybach-Str. 14-18
D-74196 Neuenstadt

including the locations according to annex

Through an audit, documented in a report, it was verified that the management system
fulfills the requirements of the following standard:
Scope: Trading of engine parts for the worldwide aftermarket

ISO 14001 : 2004 + Cor 1 : 2009

Proof has been furnished by means of an audit that the


Certificate registration no. 069998 UM requirements of ISO 9001:2008 are met.
Valid from 2015-12-29
Valid until 2018-09-14
Date of certification 2015-10-28

Validity: The certificate is valid from 2015-11-18 until 2018-09-14.

DQS GmbH

Götz Blechschmidt
Managing Director

2015-12-02
TÜV Rheinland Cert GmbH
Accredited Body: DQS GmbH, August-Schanz-Straße 21, 60433 Frankfurt am Main Am Grauen Stein · 51105 Köln

Installation of Pistons
Step by Step
Weitere technische Informationen
Test, bore and hone cylinder

Fine-bore the cylinder with fitted main bearing caps. Make a honing
allowance of approx. 0.08 mm (referred to the diameter). Well-honed
cylinder bores should have at least 20 % open graphite veins. Only use the
honing oil recommended by the honing machine manufacturer. The honing
surface
roughness
Rt (value measured by
instrument)
cylinder surface
before running
3–6 µm
Honing tools

• Prehoning: grain size 150 (material removal approx. 0.06 mm referred to the diameter)
• Finish honing: grain size 280 (material removal 0.02 mm referred to the diameter)
• Platform honing: grain size 400–600 (remove profile peaks in a few strokes applying light
contact pressure)
Only for engines with liners

Wet liner:
Clean liner flange seat in crankcase carefully, do not use cutting tools.
Flange seat A must be plane parallel and free of dirt. Treat sealing rings
carefully with assembly grease (e.g oil). It must be possible to introduce
finden Sie auf unserer Homepage.
angle should be between 40–80 degrees. Provide for a certain cylinder • Honing and brushing: use hones of grain size 120, 150, 180 for honing. For block engines the cylinder liner without great effort; avoid by all means hard impacts

Pistonrings
Rings
Ra (value measured by 0.4–0.8 µm

Piston
surface roughness to ensure perfect adherence of the oil film: there are (grey casting) bond 5-7, for liner (centrifugal casting) bond 5 max. Material removal: or moving of the liner. The liner projecting length B should be as
instrument) standard honing plateau honing Correct flange seat
three current measuring methods as outlined in Table. between 0.03 and 0.05 mm referred to the diameter. Using honing brushes removes specified by the engine manufacturer (e.g. 0.05 – 0.1 mm).
R3Z (diagram evaluation) 4–7 µm
peaks that occur on the surface of the cylinder during the final honing operation.
This requires at least ten strokes and the use of honing oil. To achieve optimum results, Dry liner:
the rotation direction of the honing machine should be reversed after half of the Apply anti-seize agent to the outside diameter of the cylinder liner.
processing time. The honing brushes reduce cylinder diameter by between 0.001 and a Dry liners have typically an overdimension compared with the cylinder
maximum of 0.01 mm. block, having to be pressed in (interference fit). The edge chamfer C in

Function and Design


Function design
Preparing

• Check the cylinder diameter at top, centre and bottom as well as in longitudinal and the case should correspond to radius D at the cylinder liner.
transversal direction (90° off-set). Incorrect flange seat
hone brushing

www.ms-motorservice.com
nominal cylinder tolerrance
dimension range to be complied with
Attention Ø 30–50 mm 0.011 mm
Clean cylinder bore and cylinder blocks after honing Ø 50–80 mm 0.013 mm
(e.g. ultrasonic cleaning). Ø 80–120 mm 0.015 mm
Ø 120–180 mm 0.018 mm

Incorrect reconditioning Maintenance faults


Piston impact on cylinder head Worn-out ring grooves
If the sealing surface of an engine block is The result: High oil consumption and high Dirt that reaches the combustion The result: High oil consumption and poor
reconditioned and a piston with standard cylinder wear (see also “Fuel Flooding”). chamber settles in the ring grooves where performance.

Incorrect reconditioning Maintenance faultsand at the flanks of the piston ring. This
compression height fitted, this may cause it causes abrasive wear in the ring grooves
mechanical impact by the piston on the
cylinder head in the case of diesel engines.
Remedy: Compliance with the correct
piston protrusion; use of correct cylinder
General results in excessive ring height clearance
Remedy: Regular air filter main-tenance,
especially in very dusty areas.
Assembly of piston and conrod Placing the piston into the cylinder bore
Piston impact
The same occurs on the
if cylinder cylinder
head gaskets with head
head gaskets. Dirtconsequently
and in the intake air
to a deterioration of the
the wrong thickness are fi tted. Due to these guidance of the piston rings in the ring
If theim-pacts,
hard sealing area of an engine
the piston block
rings start is
to flutter Consequence: High oil consumption and Dirt that reaches
grooves. The ringsthe combustion
will chamber
become bent during Consequence: High oil consumption and
reconditioned and a piston
and vibrate, dislodging withcation
the lubri standard
film high cylinder wear (see also "Fuel flooding") KOLBENSCHMIDT settles
use uses
and thepreservatives
instart ring
to grooves
flutter. that
where
If the rings do
itare
causes poor performance Check conrods for deformation and torsion using a suitable Floating pins: Assembly of conrod with fixed pin: Clean the cylinder block carefully after Anodized pistons:
compression height fitted,
and as a consequence sealing this
is may cause
no longer abrasive
not affect theseverely
engineworn wear in
oil; at the
it the ringneces
sides,
is not grooves
they saryand
can at the
break. testing instrument before installing them. The maximum Fix the pin, use the enclosed retainer rings and avoid excessive The conrod eye bore must provide for an overlap with making sure that all sliding surfaces are free For pistons with anodized piston crown, the crown must
mechanical
effectively. impact by the piston on the Remedy: Compliance with the correct piston piston ring flanks. This results in excessive Remedy: Regular air filter maintenance, tolerance must not exceed 0.02 mm per 100 mm. Put the from dirt and well oiled.
therefore to clean the pistons. Data about compression which might produce permanent deformation. Please respect to the pin 0.02–0.04 mm. Heat the conrod to not be turned to adjust the gap dimension. These pistons
cylinder head in the case of diesel engines. protrusion, use of the correct cylinder head ring height clearance and consequently to particularly in dusty areas
Ring
The same joint
occursclearance
if cylinder head too small gaskets
gaskets piston diameter, assemblyofclearance
a deterioration the guidanceand of the piston piston and the conrod in place in use a special tool. Turn the rings slightly to make sure that they 280–320 °C (no bare flame!). After oiling the pin and Compress the piston ring using a squeezer are recognizable by the black colour of the crown surface.
with the wrong thickness are fitted. Due to rings in (e.g.
assembly direction the ring grooves.
arrow) areThetorings
be will accordance with the assembly have safely engaged in the grooves. Place the joint of the retainer allowing it to cool, introduce it swiftly into the eye in order to allow the piston to slide smoothly Certain piston types with anodized crowns have, besides
The piston
these hard ring joint the
impacts, clearance
piston is compa-
rings start to The result: Premature piston ring wear, become bent during use and start to flutter. direction. Next the conrod eye
found on the piston crown. Be aware that the in running direction of the piston. using a device. Then check the correct piston fit using into the cylinder bore. Measure the gap the standard piston, pistons with reduced compression
rable to
flutter theno
and valve
longer clearance. When the
seal properly. piston seizure and high oil consumption. If the rings are severely worn at the sides,
parts are warmed up, the components are cylinder diameter comprises the piston skirt may take up the gudgeon pin. a testing instrument. dimension in the case of diesel engines and height for adjustment of the gap. In most cases,
they can break.
thermally heated which results in a change Remedy: It is essential that the minimum diameter plus assembly clearance. Slide the oiled pin gently into the abide by all means by the manufacturer´s the compression piston dimension is staged from
in length. As long as the machine is cold, joint clearances are complied with – a reduc-
For pistons with a graphite layer, deduct pin bores of the piston and the instructions. 0.2–0.6 mm.
Piston ring joint
the joint clearance preventsclearance
the pistons intoo small
tion of the joint clearance by the repair shop
eye of the conrod. Avoid any jerky
0.015–0.02 mm layer thickness from the
100° C

the cylinder from being jammed when the is not permitted.


Installation

Attention
The pistonis ring
hot.joint
If theclearance is Consequence: Premature piston ring wear, dimension measured movement.
Jammedtopiston get the stamped-on
0° C

machine
comparable to the
joint clearance
valve clearance.
is too
Warming piston seizure and high oil consumption
rings If shaped pins are specified, please use.
small when the machine is cold, there will skirt dimension. In the case of pistons
100° C
up
be the parts causes
an excessive ratethermal
of wear expansion
on the piston of Piston rings must be able to rotate freely in The result: Piston seizure, high wear and
0° C the
ring,components
sealing problems and a change
and enginein length.
failure Remedy: It is essential that the minimum graphitized according to the screen printing
their ring grooves during operation (excep- high oil consumption.
The
couldjoint clearance
occur when the when the machine
machine is hot. is joint clearances are complied with – process, measure the skirtengines).
tion: two-stroke diameter only
If the at rings
piston
cold ensures that the piston rings in the a reduction of the joint clearance by the
100° C
the specified are
measuring
blocked bypoints – smallorareas
carbon deposits dirt in Remedy: Regular air filter maintenance and
25–40 µm
cylinder will not get stuck when the
0° C
Asymmetric piston wear patternrepair shop is not permitted
machine is hot. If the joint clearance is too
the ring
without graphite grooves they are no longer able to
layer. the use of engine oil with the prescribed oil

Die Inhalte des OnlineShops sind auch in


small whenconnecting
the machine is cold, there will
Blocked
seal properlypiston rings
and will not wear uniformly. specification for the engine.
Deformed rods, which often The result: High wear, ring fractures and If the rings are clamped in the grooves, the
be highaspiston ringof wear,
enginesealing
failure,problems
100° C

occur a result can excessive oil consumption. Piston rings


sealing effectmust
is nobe able to
longer rotate freely
warranted. This Consequence: Piston seizure, high wear and
0° C
and
cause engine damage
the piston whenan
to have the engine is
incorrect hot.
atti- in their aring
causes grooves
blow-by during operation
of combustion gases on high oil consumption
tude in the cylinder. The piston rings con- Remedy: Check the connecting rod (exception: two-stroke
compression rings, andengines).
results in Ifthe
thepenet- measuring points
sequently take on an elliptical form and no for deformation and torsion prior to pistonof
ration rings are the
oil into blocked by carbon
combustion deposits
chamber Remedy: Regular air filter maintenance
Asymmetric
longer rotate in thepiston wear
piston. This pattern
results in installing it. or dirt
on in the ring grooves, they are no
oil rings. and use of engine oil with the right oil
uneven wear and piston ring fluttering. longer able to seal properly and will not specification for the engine
Bent connecting rods, which often occur as Consequence: High level of wear, ring wear uniformly. It the rings get stuck in the
a result of engine damage, cause the piston fractures and excessive oil consumption
Abnormal combustion
grooves, the sealing effect is no longer
TIPS & INFOS
SERVICE

to run at an angle in the cylinder. The piston guaranteed. This causes a blow-by of
rings consequently take on an elliptical Remedy: Check the connecting rod for

Piston damage –
combustion gases on compression rings,
form and no longer rotate in the piston. distortion and twisting before installing it Knocking combustion and glow ignition
and results in the passage of oil into the
This results in uneven wear and ring flutter. combustion chamber on oil rings.
Piston ring assembly Engine trial run After running in
Knocking combustion or glow ignitions The result: Piston seizure, loss of engine
result in excessive pressure peaks in the power and/or high oil consumption.
cylinder as well as high mechanical stress
© MS Motorservice International GmbH – 50 003842-02 – 02/15 EN

Combustion defaults
of the parts. The piston rings start to flut- Remedy: Use of high-grade fuels.

recognising and rectifying


Installation of worn-out parts ter and can break. On moly-bdenumplated

Form eines elektronischen Kataloges auf


rings, the moly-bdenum layer can break
KOLBENSCHMIDT pistons are available ready for installation. It is not necessary to Do not start the newly overhauled engine until it is assembled The quickly flowing hot oil will Information about our product range can be found in our
Knocking
away. combustion and glow ignition
Out-of-round cylinders assemble the rings which could lead to excessive strain. If you want to install a completely with all fittings and filled with oil and cooling water. clean the engine from all foreign catalogue “Pistons and Components”.
Knocking combustion and please
glow ignition Consequence:
tool. BePiston seizure,
that loss of
Installing worn parts When machining the cylinder bores, it is
essential to make sure that the geometry
The result: Poor performance, excessive
oil consumption and engine failures.
KOLBENSCHMIDT ring set in a used piston,
causes excessive pressure peaks in the
the assembly directioncylinder
of some andring types is identified
use a special aware
engine power and/or high oil consumption
with “TOP” (“TOP” should
Ensure that the engine starts at the very first starting attempt since
the first fuel revolutions are subject to critical lubricating conditions
matter that may still adhere after
the overhaul. These particles will
Further information can be obtained directly from your local
high mechanical stress on the Motorservice partner or at www.ms-motorservice.com
To
p is perfect. The piston rings can still seal
Out-of-round cylinders Fuel
face to the piston crown).
parts. flooding
Napier
The rings
piston and
rings oiltocontrol
start flutter andrings should
Remedy: be Use installed
of high-gradesuch
fuels and decisive for the subsequent operating behaviour of the engine. collect in the engine oil and oil
slightly oval cylinders. However, sealing Remedy: Observe the tightening specifi-
can break.
that the oil is scraped down Withbottom
to the molybdenum-coated
skirt end.rings,
See to The
it that theHigh
joint
ringends of wear, After warm running of the engine, check it again for leaks, ignition, filter. A distance of 50 km is
www.ms-motorservice.com

becomes more difficult with out- of-rounds cations for the cylinder head or exclude The oil film is washed off due to incomplete result: and cylinder
When machining the cylinder bores, it is Consequence: Poor performance, excessive the molybdenum layer can break away.
of the 3rdto
ormake
4th order. These out-of-rounds during cylinder machining. the spiral expander in combustion
the oil control
of the ring arefuel
in-jected always locatedhigh
or to exces- opposite to the ring
oil consumption. valve clearance, etc. Then start running the engine in on the test sufficient for most of all dirt
essential sure that theare often is
geometry oil consumption and engine damage
caused by tension stressing sive injected
joint. In the case of tripartite fuel. This
oil rings causes mixed
(expander fric- with lateral segments), the
spring bench or in the vehicle. Operate the engine at not more than two- particles to accumulate. Do not
perfect. Piston rings can stillfrom
seal the cylin-
slightly Out-of-rounds: tion or even dry friction of the piston in the Remedy: Correct function and setting of
p

der head bolts. The crescent-shaped gap


To

oval cylinders. Remedy: Observe cylinder head tightening Sliding friction


segment joints shouldcylinder.
be off-set by about 120°. thirds of its nominal speed at moderate load changes; later on, the operate the engine for more than
caused by out-of-roundness between the
However, sealing becomes difficult for 3rd specifications or eliminate out-of-roundness
The metal parts rub against each the fuel system.
number of revolutions may be increased gradually. 500 km with the first oil fill. The Motorservice Group is the sales organisation for the global aftermarket activities of
piston ring and the cylinder will result in other without a protective oil film.
and 4th order out-of-roundness. These
leakages.
during cylinder machining
Fuel flooding KSPG (Kolbenschmidt Pierburg). It is one of the leading suppliers of engine components for
often occur due to tensile stresses from the
cylinder head bolts. The crescent-shaped Out-of-roundness: the independent aftermarket, including the premium brands KOLBENSCHMIDT, PIERBURG and
The oil film is washed off due to incomplete Consequence: High ring and cylinder wear,
gaps caused by out-of-roundness between
3rd order 4th order combustion of the injected fuel or too much high oil consumption TRW Engine Components, as well as the BF brand. Our comprehensive product range allows
the piston ring and cylinder will result in Mixed friction
Trial run

leaks.
injected fuel. This causes mixed or dry our customers to obtain engine components from a single source.
friction of the piston in the cylinder. The Remedy: Correct function and adjustment

der „Motorservice Product Disc“ verfügbar.


Ring joint clearance too great Liquid friction
metal parts rub against one another. of the fuel system
An excessive joint clearance on the piston Remedy:
3rd order Replace
4thworn-out
order pistons and
rings appears after a long running period cylinders.
and high wear on the cylinder and piston
Piston
rings. The ring joint clearance
joint clearance is too great if ittoo great
has doubled its size compared to its new
An excessive joint clearance on the piston Remedy: Replace worn pistons and Mixed friction
condition. Clearance exten-sions of up to
rings appears after a long service life and cylinders
0.3 mm are irrelevant. They contribute
high wear on the cylinders and piston rings.
01/15(122016)

neither to a loss of engine power nor to


100° C
The joint clearance is too great if it has
excessive oil consumption. Slightly en-
EN

0° C doubled its size compared to its new


larged piston ring joint clearances are often
– EN ––02/15

condition. Increases in clearance of up to d


over-estimated. On this topic, also see
100° C
0.3 mm are negligible. They contribute
“Ring joint clearance too small”.
003 928-02

100°
0° C
C
neither to a notable loss of engine power
nor to high oil consumption. The
– 50928-02

significance of a slightly enlarged piston


0° C

d
ring joint clearance is often over-estimated. Further details on this subject can be found in our brochure
– 50 003

100° C
Worn-out
See also "Pistoncylinders
ring joint clearance too Details
"Pistonon thisfor
Rings subject can be found
Combustion in our brochure
Engines".
GmbHGmbH
www.ms-motorservice.com

small". „Piston Rings


Or ask your forMotorservice
local Combustion Engines“.
partner. We have also provided a lot more

Kontaktieren Sie hierzu Ihren Ansprech-


0° C

If new pistons and piston rings are fitted The result: Higher oil consumption and
www.ms-motorservice.com
International

into a worn-out cylinder, the piston rings premature wear. information


Further for you at
information canwww.ms-motorservice.com
be obtained directly from and
youron our Technipedia
local
at www.technipedia.info.
International

Worn cylinders
often hit the upper wear edge of the cylin-
der. As a result, the piston rings start to flut- Remedy: Replacement of the cylinder liner
Motorservice partner or at www.ms-motorservice.com
MS Motorservice

ternew
If andpistons
can noand
longer sealrings
piston effectively.
are installed or remachine the
Consequence: cylinder
High bore (drilling,
oil consumption and
© MS©Motorservice

in a worn cylinder, the piston rings often hit honing). wear


premature
Alsoupper
the see “Piston impact
wear edge on cylinder.
of the cylinder head”
As a
and “Worn-out
result, ring
the piston grooves”.
rings start to flutter and Remedy: Replace worn cylinders or rebore
The Motorservice Group is the sales organisation for the global aftermarket
no longer seal properly. cylinders
activities of KSPGGroup
The Motorservice (Kolbenschmidt
is the salesPierburg). It is for
organisation onetheof the leading suppliers
worldwide
See also "Piston impact on the cylinder of engine components
aftermarket activities offor the independent
Rheinmetall aftermarket,
Automotive. including
It is a leading the
supplier
head" and "Dirt in the intake air"
of engine brands
premium components for the independent
KOLBENSCHMIDT, PIERBURGaftermarket. With the
and TRW Engine premium
Components,
brands
as Kolbenschmidt,
well as the BF brand.Pierburg, TRW Engineproduct
Our comprehensive Componentsrange and theour
allows BF brand,
Motorservice
customers offers its
to obtain customers
engine a wide and
components fromcomprehensive
a single source.range of top
quality products from a single source.

ks_50003928.indd 1 11.01.17 16:43


partner.

2
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DEUTSCH
Inhaltsverzeichnis Seite
Wichtige Hinweise 2

Rheinmetall Automotive Qualitätsmanagement 2


Renommierter Zulieferer der internationa- Know-how Transfer – Fachwissen vom Experten 4
len Automobilindustrie 1. Gleitlager 6
Rheinmetall Automotive ist die Mobilitäts­
2. Hinweise zur Benutzung des Katalogs 8
sparte des Technologiekonzerns
­Rheinmetall Group. Mit seinen Premium­ 3. Lagerbauarten im Motor 12
marken ­Kolbenschmidt, Pierburg und 4. Programmergänzungen 73
­Motorservice nimmt ­Reinmetall ­Automotive
5. Herstellerverzeichnis 83
in den Bereichen Luftversorgung, Schad-
stoffreduzierung und Pumpen sowie bei 6. Produktprogramm 87
der Entwicklung, Fertigung und Ersatz- 7.  inzelteil – Paar/Satz
E 1613
teillieferung von Kolben, Motorblöcken (Piece – Pair/Set/Make/Position)
und Gleitlagern weltweit Spitzenpositionen 8. Paar – Satz (Pair – Set/Make/Position) 1699
auf den jeweiligen Märkten ein. Niedrige
9. Satz (Set/Make/Position) 1717
Schadstoffemission, günstiger Kraftstoff­
verbrauch, Zuverlässigkeit, Qualität 10. V
 ergleichsliste Federal-Mogul & Glyco-Nr. 1755
und Sicherheit sind die maßgeblichen Kolbenschmidt Nr.
Antriebsfaktoren für die Innovationen von (Federal-Mogul & Glyco-No. – Kolbenschmidt No.)
­Rheinmetall  Automotive. 11. Reklamation/Reklamationsformular
12. Verkaufs- und Lieferbedingungen

Motorservice Gruppe
Qualität und Service aus einer Hand
Die Motorservice Gruppe ist die
Vertriebsorganisation für die welt-
weiten Aftermarket-Aktivitäten von
­Rheinmetall ­Automotive. Sie ist ein
führender Anbieter von Motor­komponenten
für den freien Ersatzteilmarkt. Mit den
Premiummarken ­Kolbenschmidt, ­Pierburg,
TRW Engine ­Components sowie der
Marke BF bietet Motorservice seinen Kun-
den aus einer Hand ein breites und tiefes
Sortiment in Spitzenqualität. Als Problem-
löser für Handel und Werkstatt verfügt sie
zudem über ein umfangreiches Leistungs-
paket. Kunden von ­Motorservice profitieren
so vom geballten technischen Know-how
eines großen internationalen Automobilzu-
lieferers.

3
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DEUTSCH

Know-how
Transfer
transfer

Fachwissen vom Experten


Weltweite Schulungen Technische Informationen Technische Videos
Direkt vom Hersteller Aus der Praxis für die Praxis Professioneller Einbau anschaulich
Jährlich profitieren rund 4.500 Mechaniker Mit unseren Produkt Informationen, Service erklärt
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oder auch in unseren Schulungszentren in neuesten Stand der Technik. hinweise und Systemerklärungen rund um
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und vieles mehr. Support und vieles mehr.

4
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DEUTSCH
PI 1575
SI 1210
For
For technical
technical personnel
personnel only!
only!
Page
Page 1/2
1/2

Engine bearings with polymer coating Tips and tricks ...


…for correct installation and long service life of the Systemkomponenten
und Service
new short block

für eine fachgerechte Reparatur


• Please
Please note
note that
that cylinder
cylinder heads
heads which
which •
• Check
Check the
the correct
correct operation
operation of
of the
the vis-
vis- until
until oil
oil pressure
pressure has
has built
built up,
up, so
so that
that all
all
may
may bebe included
included in
in the
the delivery
delivery are
are not
not cous
cous fan.
fan. bearing
bearing points
points have
have been
been supplied
supplied with
with
fully
fully assembled.
assembled. These
These must
must be
be aligned
aligned •
• Clean
Clean water
water cooler
cooler and
and check
check for
for blocka-
blocka- oil
oil before
before initial
initial start-up.
start-up.
with
with the
the exhaust
exhaust manifold
manifold or
or intake
intake • Check for
• Check for correct
correct function
function in
in the
the oil
oil
manifold
manifold and
and the
the cylinder
cylinder head
head bolts
bolts pump,
pump, oil
oil pressure
pressure control
control valve,
valve, water
water
must
must bebe tightened
tightened according
according to
to the
the charge
charge air
air cooler
cooler thoroughly
thoroughly and
and check
check pump
pump and
and vibration
vibration damper.
damper.
for blockages,
for blockages, itit is
is imperative
imperative to
to replace
replace •

• Clean all
• Clean all attachments
attachments thoroughly
thoroughly before
before this in
this in the
the case
case of
of previous
previous turbocharger
turbocharger --
installation
installation and
and check
check for
for damage.
damage. damage.
damage. cle
cle manufacturer.
manufacturer.

• Clean
Clean oil
oil cooler
cooler thoroughly
thoroughly and
and check
check for
for • Check
• Check engine
engine monitoring
monitoring instruments
instruments for
for

EN
04/15EN
blockages,
blockages, itit is
is imperative
imperative to
to replace
replace this
this correct operation
correct operation andand replace
replace in
in case
case of
of

GmbH––04/15
in
in the
the case
case of
of previous
previous engine
engine damage.
damage. defects.
defects.

www.ms-motorservice.com
• • Never start
start the
the engine
engine without
without oil
oil and
and

www.ms-motorservice.com
• • Never

InternationalGmbH
coolant.
coolant.

MotorserviceInternational
• Check connections
• Check connections and
and intake
intake pipes
pipes to
to • Manually supply
• Manually supply (inject)
(inject) the
the engine
engine oil
oil
the
the engine
engine for
for tightness.
tightness.
MSMotorservice •
• Check
Check injection
injection system,
system, set
set start
start of
of with
with oil
oil and
and crank
crank without
without injection
injection
delivery
delivery according
according toto manufacturer's
manufacturer's nozzles (max.
nozzles (max. 10–15
10–15 seconds
seconds per
per
sequence to
sequence to avoid
avoid damage
damage toto the
the starter)
starter)
©MS
©

www.ms-motorservice.com

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Fachwissen direkt vom Experten. rund um unsere Produkte.

5
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DEUTSCH

1. Gleitlager

Massivlager Zweistofflager
Zuverlässige Dauerläufer Allrounder mit Nehmerqualitäten
Diese aus einer speziellen Bronzelegierung Zweistofflager von Kolbenschmidt zeichnen
hergestellten Buchsen kommen haupt- sich durch eine hohe Verschleiß- und Kor-
sächlich im Pleuel und bei der Lagerung rosionsbeständigkeit aus. Zweistofflager
der Nockenwelle zum Einsatz. Sie zeichnen kommen vor allem an niedrig bis mittelbe-
sich durch Ihre hohe Ermüdungsfestigkeit lasteten Lagerstellen zum Einsatz.
aus.

Zweistofflager
Technische Informationen zu
Produkten, Einbau und
Stahl-Alu
Einlauf:finden sie unter:
www.ms-motorservice.com
Rücken: Stahl
Lagermaterial: Aluminium

6
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DEUTSCH
Dreistofflager
Halten dem größten Druck stand
Die je Einsatzort und -art unterschiedlichen Sputter- oder Gleitlackschichten werden
Gleitschichten garantieren eine lange hauptsächlich in höher belasteten Motoren
Lebensdauer – auch unter erschwer- verwendet. Hier kommen sie vor allem als
ten Bedingungen. Lager mit Galvanik-, Haupt- und Pleuellager zum Einsatz.

Dreistofflager Dreistofflager Dreistofflager

Galvanik Gleitlack Sputter

Rücken: Stahl Rücken: Stahl Rücken: Stahl


Lagermaterial: Bronze Lagermaterial: Aluminium oder Bronze Lagermaterial: Messing oder Bronze
Zwischenschicht Laufschicht: Gleitlack Zwischenschicht (bei Bronze)
Laufschicht: Galvanik Laufschicht: Sputter

7
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DEUTSCH

2. Hinweise zur Benutzung des Katalogs

Motorenindex
Am Anfang des jeweiligen Herstel- Die Motoren­bezeich­nungen sind auf­
lers befindet sich eine ausführliche steigend alpha­numerisch sortiert.
Suchhilfe.

Motor Positionsnummer

Fahrzeugindex
Am Anfang des jeweiligen Herstel- Die Fahrzeuge sind aufsteigend alpha­
lers befindet sich eine ausführliche numerisch sortiert.
Suchhilfe.

Fahrzeug / Modellreihe Positionsnummer

8
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DEUTSCH
Produktdaten
Die Katalogseiten bestehen aus den nach­
stehend aufgeführten Informationsblöcken:

Positionsnummer Piktogrammzeile Hersteller

Hersteller

Gleitlagerdaten (mm) Motorenzeile

Motorenzeile

Positionsnummer Baujahr von bis Kolbenfamilien für die Verdichtungsverhältnis


(fortlaufende Nummerierung aufgeführten Motoren.
innerhalb eines Herstellers) Details zur Verwendung
siehe Kolben­Katalog.
Zylinder-Nenn-Ø Ladeart* Hub

Bemerkungen Motornummer/ Zylinderanzahl Hubraum Hinweis auf


Seriennummer Bemerkungen

Motorbezeichnung mit Kraftstoffart* Ventilanzahl Leistung von bis


Kat-Ausführung/Schadstoffart

* siehe Abkürzungsverzeichnis

9
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DEUTSCH

Gleitlagerdaten

Hersteller

Lagerbauart (Standard-) Wellendurchmesser (mm)


max.
min.

Gehäusebohrung (mm)
max.
min.

Hinweis auf­
Werkstoffe* Lagerbreite (mm) Reparaturstufen Bemerkungen

Lagerstelle Bemerkungen Art.-Nr. für


zum ­Gleitlager Lagerpaar
und Einzelteil

Einbaulage: Standardwand- Art.-Nr. für Lagersatz


dicke (mm) und Anlaufscheiben
= oben
= unten

* siehe Abkürzungsverzeichnis

10
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DEUTSCH
Gleitlagerdaten

Axialspiel Wangenabstandmaß Bemerkung: Einschränkung (Baujahr bzw.


der Kurbelwelle (mm) Motornummer) des Produktes zum Motor

Anzahl der Lagerpaare


bzw. Einzellager
pro Motor

Lagerhälften-Nummer Anlaufscheiben­dicke (mm) Inhalt der


Lagersätze pro Motor
Lagerpaar bzw. Reparaturstufe mit
Lagersatz-Nummer Bearbeitungszugabe

Anlaufscheiben- Anlaufscheiben-
Innendurchmesser (mm) Außendurchmesser (mm)

Abbildung eines Gleitlagers

11
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DEUTSCH

3. Lagerbauarten im Motor

2
3

6
5

1 Kipphebelbuchsen (KH-B) 2 Pleuelbuchsen (PL-B) 3 Pleuellager (PL) 4 Hauptlager (HL)

5 Passlager (PASS-L) 6 Anlaufscheiben (AS) 7 Nockenwellenlager (NW-L)

12
Basic information

ENGLISH

EN

Basic information

13
Basic information

Important information In addition, we do not accept liability for final inspection, we will of course under-
The information in this catalogue has been the correctness of the data or the sui- take to repair the engine or replace the
put together with care, but is not binding. tability of the product for the intended faulty product within the limitation period.
We cannot accept liability for the correct- purpose. To ensure the above, the expert We must be advised in writing of com-
ness of the information. In particular, the advice of the manufacturer or its autho- plaints of this nature within 30 days of the
possibility of modifications to equipment rised repair shop must be obtained in all occurrence of the fault.
by vehicle or engine manufacturers, cases before installation. The limitation period for claims for defects
or changes to designations, cannot be The parts offered in the catalogue are not is 12 months, commencing from the deli-
excluded. We always welcome feedback intended for use in aircraft. If using in very of the item.
about any errors in the catalogue, and will marine or stationary engines, please note Claims for defects shall be void if the
ENGLISH

correct them in future editions. Names, that different engine parts (e.g. pistons) delivered item has been modified by a third
descriptions and numbers of vehicles, may be used, even if the engine designa- party or parts from other manufacturers
manufacturers, etc. are included only for tion is the same. have been installed, unless the defect is
the purpose of comparison. We reserve the not related to such modifications. Further-
right to change the product specifications, Reprinting, imitation and reproduction of more, they shall be void if the item was not
materials and appearance of our products this catalogue in whole or in part is permit- handled or installed in accordance with the
at any time. ted only with our written consent and with applicable regulations.
reference to the source. On publication Normal wear and tear and damage resul-
This will not affect the function or intended of this catalogue, all previous versions ting from improper handling are excepted
purpose stated in the catalogue. Illustra- become invalid. from the warranty.
tions, schematic diagrams and other data
are provided for the purpose of explanation Changes and errors excepted.
and depiction, and cannot be taken as the Environmental management
basis for installation, design or the scope Handling resources responsibly, protecting
of supply. Original spare part numbers Quality management our environment and compliance with all
of vehicle and engine manufacturers are As a sign that our quality management the relevant legal obligations are extremely
provided for comparison only. They are satisfies the requirements of the relevant important for long-term co-operation with
not designations of origin and must not be international standards, we are certified to all our partners. This is what motivated
used in relation to third parties. We cannot ISO 9001. us to satisfy the requirement standard for
accept liability for the use of comparison environmental management systems ISO
lists because of possible changes and/or In the event of material or production faults 14001, and to get our organisation certi-
differences in dimensions among indivi- despite continuous checks during the fied accordingly.
dual manufacturers in particular. production process and the comprehensive

CERTIFICATE
This is to certify that

MS Motorservice International GmbH


Wilhelm-Maybach-Straße 14-18
74196 Neuenstadt
Certificate
Germany
Standard ISO 9001:2008
Certificate Registr. No. 01 100 4255
has implemented and maintains an Environmental Management System.

Certificate Holder:

Scope:
Assembling and trading of Engine Parts for the Aftermarket MS Motorservice International GmbH
Wilhelm-Maybach-Str. 14-18
D-74196 Neuenstadt

including the locations according to annex

Through an audit, documented in a report, it was verified that the management system
fulfills the requirements of the following standard:
Scope: Trading of engine parts for the worldwide aftermarket

ISO 14001 : 2004 + Cor 1 : 2009

Proof has been furnished by means of an audit that the


Certificate registration no. 069998 UM requirements of ISO 9001:2008 are met.
Valid from 2015-12-29
Valid until 2018-09-14
Date of certification 2015-10-28

Validity: The certificate is valid from 2015-11-18 until 2018-09-14.

DQS GmbH

Götz Blechschmidt
Managing Director

2015-12-02
TÜV Rheinland Cert GmbH
Accredited Body: DQS GmbH, August-Schanz-Straße 21, 60433 Frankfurt am Main Am Grauen Stein · 51105 Köln

Installation of Pistons
Step by Step
You can find further technical
Test, bore and hone cylinder

Fine-bore the cylinder with fitted main bearing caps. Make a honing
allowance of approx. 0.08 mm (referred to the diameter). Well-honed
cylinder bores should have at least 20 % open graphite veins. Only use the
honing oil recommended by the honing machine manufacturer. The honing
surface
roughness
Rt (value measured by
instrument)
cylinder surface
before running
3–6 µm
Honing tools

• Prehoning: grain size 150 (material removal approx. 0.06 mm referred to the diameter)
• Finish honing: grain size 280 (material removal 0.02 mm referred to the diameter)
• Platform honing: grain size 400–600 (remove profile peaks in a few strokes applying light
contact pressure)
Only for engines with liners

Wet liner:
Clean liner flange seat in crankcase carefully, do not use cutting tools.
Flange seat A must be plane parallel and free of dirt. Treat sealing rings
carefully with assembly grease (e.g oil). It must be possible to introduce
information on our homepage.
angle should be between 40–80 degrees. Provide for a certain cylinder • Honing and brushing: use hones of grain size 120, 150, 180 for honing. For block engines the cylinder liner without great effort; avoid by all means hard impacts

Pistonrings
Rings
Ra (value measured by 0.4–0.8 µm

Piston
surface roughness to ensure perfect adherence of the oil film: there are (grey casting) bond 5-7, for liner (centrifugal casting) bond 5 max. Material removal: or moving of the liner. The liner projecting length B should be as
instrument) standard honing plateau honing Correct flange seat
three current measuring methods as outlined in Table. between 0.03 and 0.05 mm referred to the diameter. Using honing brushes removes specified by the engine manufacturer (e.g. 0.05 – 0.1 mm).
R3Z (diagram evaluation) 4–7 µm
peaks that occur on the surface of the cylinder during the final honing operation.
This requires at least ten strokes and the use of honing oil. To achieve optimum results, Dry liner:
the rotation direction of the honing machine should be reversed after half of the Apply anti-seize agent to the outside diameter of the cylinder liner.
processing time. The honing brushes reduce cylinder diameter by between 0.001 and a Dry liners have typically an overdimension compared with the cylinder
maximum of 0.01 mm. block, having to be pressed in (interference fit). The edge chamfer C in

Function and Design


Function design
Preparing

• Check the cylinder diameter at top, centre and bottom as well as in longitudinal and the case should correspond to radius D at the cylinder liner.
transversal direction (90° off-set). Incorrect flange seat
hone brushing

www.ms-motorservice.com
nominal cylinder tolerrance
dimension range to be complied with
Attention Ø 30–50 mm 0.011 mm
Clean cylinder bore and cylinder blocks after honing Ø 50–80 mm 0.013 mm
(e.g. ultrasonic cleaning). Ø 80–120 mm 0.015 mm
Ø 120–180 mm 0.018 mm

Incorrect reconditioning Maintenance faults


Piston impact on cylinder head Worn-out ring grooves
If the sealing surface of an engine block is The result: High oil consumption and high Dirt that reaches the combustion The result: High oil consumption and poor
reconditioned and a piston with standard cylinder wear (see also “Fuel Flooding”). chamber settles in the ring grooves where performance.

Incorrect reconditioning Maintenance faultsand at the flanks of the piston ring. This
compression height fitted, this may cause it causes abrasive wear in the ring grooves
mechanical impact by the piston on the
cylinder head in the case of diesel engines.
Remedy: Compliance with the correct
piston protrusion; use of correct cylinder
General results in excessive ring height clearance
Remedy: Regular air filter main-tenance,
especially in very dusty areas.
Assembly of piston and conrod Placing the piston into the cylinder bore
Piston impact
The same occurs on the
if cylinder cylinder
head gaskets with head
head gaskets. Dirtconsequently
and in the intake air
to a deterioration of the
the wrong thickness are fi tted. Due to these guidance of the piston rings in the ring
If theim-pacts,
hard sealing area of an engine
the piston block
rings start is
to flutter Consequence: High oil consumption and Dirt that reaches
grooves. The ringsthe combustion
will chamber
become bent during Consequence: High oil consumption and
reconditioned and a piston
and vibrate, dislodging withcation
the lubri standard
film high cylinder wear (see also "Fuel flooding") KOLBENSCHMIDT settles
use uses
and thepreservatives
instart ring
to grooves
flutter. that
where
If the rings do
itare
causes poor performance Check conrods for deformation and torsion using a suitable Floating pins: Assembly of conrod with fixed pin: Clean the cylinder block carefully after Anodized pistons:
compression height fitted,
and as a consequence sealing this
is may cause
no longer abrasive
not affect theseverely
engineworn wear in
oil; at the
it the ringneces
sides,
is not grooves
they saryand
can at the
break. testing instrument before installing them. The maximum Fix the pin, use the enclosed retainer rings and avoid excessive The conrod eye bore must provide for an overlap with making sure that all sliding surfaces are free For pistons with anodized piston crown, the crown must
mechanical
effectively. impact by the piston on the Remedy: Compliance with the correct piston piston ring flanks. This results in excessive Remedy: Regular air filter maintenance, tolerance must not exceed 0.02 mm per 100 mm. Put the from dirt and well oiled.
therefore to clean the pistons. Data about compression which might produce permanent deformation. Please respect to the pin 0.02–0.04 mm. Heat the conrod to not be turned to adjust the gap dimension. These pistons
cylinder head in the case of diesel engines. protrusion, use of the correct cylinder head ring height clearance and consequently to particularly in dusty areas
Ring
The same joint
occursclearance
if cylinder head too small gaskets
gaskets piston diameter, assemblyofclearance
a deterioration the guidanceand of the piston piston and the conrod in place in use a special tool. Turn the rings slightly to make sure that they 280–320 °C (no bare flame!). After oiling the pin and Compress the piston ring using a squeezer are recognizable by the black colour of the crown surface.
with the wrong thickness are fitted. Due to rings in (e.g.
assembly direction the ring grooves.
arrow) areThetorings
be will accordance with the assembly have safely engaged in the grooves. Place the joint of the retainer allowing it to cool, introduce it swiftly into the eye in order to allow the piston to slide smoothly Certain piston types with anodized crowns have, besides
The piston
these hard ring joint the
impacts, clearance
piston is compa-
rings start to The result: Premature piston ring wear, become bent during use and start to flutter. direction. Next the conrod eye
found on the piston crown. Be aware that the in running direction of the piston. using a device. Then check the correct piston fit using into the cylinder bore. Measure the gap the standard piston, pistons with reduced compression
rable to
flutter theno
and valve
longer clearance. When the
seal properly. piston seizure and high oil consumption. If the rings are severely worn at the sides,
parts are warmed up, the components are cylinder diameter comprises the piston skirt may take up the gudgeon pin. a testing instrument. dimension in the case of diesel engines and height for adjustment of the gap. In most cases,
they can break.
thermally heated which results in a change Remedy: It is essential that the minimum diameter plus assembly clearance. Slide the oiled pin gently into the abide by all means by the manufacturer´s the compression piston dimension is staged from
in length. As long as the machine is cold, joint clearances are complied with – a reduc-
For pistons with a graphite layer, deduct pin bores of the piston and the instructions. 0.2–0.6 mm.
Piston ring joint
the joint clearance preventsclearance
the pistons intoo small
tion of the joint clearance by the repair shop
eye of the conrod. Avoid any jerky
0.015–0.02 mm layer thickness from the
100° C

the cylinder from being jammed when the is not permitted.


Installation

Attention
The pistonis ring
hot.joint
If theclearance is Consequence: Premature piston ring wear, dimension measured movement.
Jammedtopiston get the stamped-on
0° C

machine
comparable to the
joint clearance
valve clearance.
is too
Warming piston seizure and high oil consumption
rings If shaped pins are specified, please use.
small when the machine is cold, there will skirt dimension. In the case of pistons
100° C
up
be the parts causes
an excessive ratethermal
of wear expansion
on the piston of Piston rings must be able to rotate freely in The result: Piston seizure, high wear and
0° C the
ring,components
sealing problems and a change
and enginein length.
failure Remedy: It is essential that the minimum graphitized according to the screen printing
their ring grooves during operation (excep- high oil consumption.
The
couldjoint clearance
occur when the when the machine
machine is hot. is joint clearances are complied with – process, measure the skirtengines).
tion: two-stroke diameter only
If the at rings
piston
cold ensures that the piston rings in the a reduction of the joint clearance by the
100° C
the specified are
measuring
blocked bypoints – smallorareas
carbon deposits dirt in Remedy: Regular air filter maintenance and
25–40 µm
cylinder will not get stuck when the
0° C
Asymmetric piston wear patternrepair shop is not permitted
machine is hot. If the joint clearance is too
the ring
without graphite grooves they are no longer able to
layer. the use of engine oil with the prescribed oil

The contents of the OnlineShop are also


small whenconnecting
the machine is cold, there will
Blocked
seal properlypiston rings
and will not wear uniformly. specification for the engine.
Deformed rods, which often The result: High wear, ring fractures and If the rings are clamped in the grooves, the
be highaspiston ringof wear,
enginesealing
failure,problems
100° C

occur a result can excessive oil consumption. Piston rings


sealing effectmust
is nobe able to
longer rotate freely
warranted. This Consequence: Piston seizure, high wear and
0° C
and
cause engine damage
the piston whenan
to have the engine is
incorrect hot.
atti- in their aring
causes grooves
blow-by during operation
of combustion gases on high oil consumption
tude in the cylinder. The piston rings con- Remedy: Check the connecting rod (exception: two-stroke
compression rings, andengines).
results in Ifthe
thepenet- measuring points
sequently take on an elliptical form and no for deformation and torsion prior to pistonof
ration rings are the
oil into blocked by carbon
combustion deposits
chamber Remedy: Regular air filter maintenance
Asymmetric
longer rotate in thepiston wear
piston. This pattern
results in installing it. or dirt
on in the ring grooves, they are no
oil rings. and use of engine oil with the right oil
uneven wear and piston ring fluttering. longer able to seal properly and will not specification for the engine
Bent connecting rods, which often occur as Consequence: High level of wear, ring wear uniformly. It the rings get stuck in the
a result of engine damage, cause the piston fractures and excessive oil consumption
Abnormal combustion
grooves, the sealing effect is no longer
TIPS & INFOS
SERVICE

to run at an angle in the cylinder. The piston guaranteed. This causes a blow-by of
rings consequently take on an elliptical Remedy: Check the connecting rod for

Piston damage –
combustion gases on compression rings,
form and no longer rotate in the piston. distortion and twisting before installing it Knocking combustion and glow ignition
and results in the passage of oil into the
This results in uneven wear and ring flutter. combustion chamber on oil rings.
Piston ring assembly Engine trial run After running in
Knocking combustion or glow ignitions The result: Piston seizure, loss of engine
result in excessive pressure peaks in the power and/or high oil consumption.
cylinder as well as high mechanical stress
© MS Motorservice International GmbH – 50 003842-02 – 02/15 EN

Remedy: Use of high-grade fuels.


Combustion defaults
of the parts. The piston rings start to flut-

recognising and rectifying


Installation of worn-out parts ter and can break. On moly-bdenumplated

available as an electronic catalogue on


rings, the moly-bdenum layer can break
KOLBENSCHMIDT pistons are available ready for installation. It is not necessary to Do not start the newly overhauled engine until it is assembled The quickly flowing hot oil will Information about our product range can be found in our
Knocking
away. combustion and glow ignition
Out-of-round cylinders assemble the rings which could lead to excessive strain. If you want to install a completely with all fittings and filled with oil and cooling water. clean the engine from all foreign catalogue “Pistons and Components”.
Knocking combustion and please
glow ignition Consequence:
tool. BePiston seizure,
that loss of
Installing worn parts When machining the cylinder bores, it is
essential to make sure that the geometry
The result: Poor performance, excessive
oil consumption and engine failures.
KOLBENSCHMIDT ring set in a used piston,
causes excessive pressure peaks in the
the assembly directioncylinder
of some andring types is identified
use a special aware
engine power and/or high oil consumption
with “TOP” (“TOP” should
Ensure that the engine starts at the very first starting attempt since
the first fuel revolutions are subject to critical lubricating conditions
matter that may still adhere after
the overhaul. These particles will
Further information can be obtained directly from your local
high mechanical stress on the Motorservice partner or at www.ms-motorservice.com
To
p is perfect. The piston rings can still seal
Out-of-round cylinders Fuel
face to the piston crown).
parts. flooding
Napier
The rings
piston and
rings oiltocontrol
start flutter andrings should
Remedy: be Use installed
of high-gradesuch
fuels and decisive for the subsequent operating behaviour of the engine. collect in the engine oil and oil
slightly oval cylinders. However, sealing Remedy: Observe the tightening specifi-
can break.
that the oil is scraped down Withbottom
to the molybdenum-coated
skirt end.rings,
See to The
it that theHigh
joint
ringends of wear, After warm running of the engine, check it again for leaks, ignition, filter. A distance of 50 km is
www.ms-motorservice.com

becomes more difficult with out- of-rounds cations for the cylinder head or exclude The oil film is washed off due to incomplete result: and cylinder
When machining the cylinder bores, it is Consequence: Poor performance, excessive the molybdenum layer can break away.
of the 3rdto
ormake
4th order. These out-of-rounds during cylinder machining. the spiral expander in combustion
the oil control
of the ring arefuel
in-jected always locatedhigh
or to exces- opposite to the ring
oil consumption. valve clearance, etc. Then start running the engine in on the test sufficient for most of all dirt
essential sure that theare often is
geometry oil consumption and engine damage
caused by tension stressing sive injected
joint. In the case of tripartite fuel. This
oil rings causes mixed
(expander fric- with lateral segments), the
spring bench or in the vehicle. Operate the engine at not more than two- particles to accumulate. Do not
perfect. Piston rings can stillfrom
seal the cylin-
slightly Out-of-rounds: tion or even dry friction of the piston in the Remedy: Correct function and setting of
p

der head bolts. The crescent-shaped gap


To

oval cylinders. Remedy: Observe cylinder head tightening Sliding friction


segment joints shouldcylinder.
be off-set by about 120°. thirds of its nominal speed at moderate load changes; later on, the operate the engine for more than
caused by out-of-roundness between the
However, sealing becomes difficult for 3rd specifications or eliminate out-of-roundness
The metal parts rub against each the fuel system.
number of revolutions may be increased gradually. 500 km with the first oil fill. The Motorservice Group is the sales organisation for the global aftermarket activities of
piston ring and the cylinder will result in other without a protective oil film.
and 4th order out-of-roundness. These
leakages.
during cylinder machining
Fuel flooding KSPG (Kolbenschmidt Pierburg). It is one of the leading suppliers of engine components for
often occur due to tensile stresses from the
cylinder head bolts. The crescent-shaped Out-of-roundness: the independent aftermarket, including the premium brands KOLBENSCHMIDT, PIERBURG and
The oil film is washed off due to incomplete Consequence: High ring and cylinder wear,
gaps caused by out-of-roundness between
3rd order 4th order combustion of the injected fuel or too much high oil consumption TRW Engine Components, as well as the BF brand. Our comprehensive product range allows
the piston ring and cylinder will result in Mixed friction
Trial run

leaks.
injected fuel. This causes mixed or dry our customers to obtain engine components from a single source.
friction of the piston in the cylinder. The Remedy: Correct function and adjustment

the “Motorservice Product Disc”. To obtain


Ring joint clearance too great Liquid friction
metal parts rub against one another. of the fuel system
An excessive joint clearance on the piston Remedy:
3rd order Replace
4thworn-out
order pistons and
rings appears after a long running period cylinders.
and high wear on the cylinder and piston
Piston
rings. The ring joint clearance
joint clearance is too great if ittoo great
has doubled its size compared to its new
An excessive joint clearance on the piston Remedy: Replace worn pistons and Mixed friction
condition. Clearance exten-sions of up to
rings appears after a long service life and cylinders
0.3 mm are irrelevant. They contribute
high wear on the cylinders and piston rings.
01/15(122016)

neither to a loss of engine power nor to


100° C
The joint clearance is too great if it has
excessive oil consumption. Slightly en-
EN

0° C doubled its size compared to its new


larged piston ring joint clearances are often
– EN ––02/15

condition. Increases in clearance of up to d


over-estimated. On this topic, also see
100° C
0.3 mm are negligible. They contribute
“Ring joint clearance too small”.
003 928-02

100°
0° C
C
neither to a notable loss of engine power
nor to high oil consumption. The
– 50928-02

significance of a slightly enlarged piston


0° C

d
ring joint clearance is often over-estimated. Further details on this subject can be found in our brochure
– 50 003

100° C
Worn-out
See also "Pistoncylinders
ring joint clearance too Details
"Pistonon thisfor
Rings subject can be found
Combustion in our brochure
Engines".
GmbHGmbH
www.ms-motorservice.com

small". „Piston Rings


Or ask your forMotorservice
local Combustion Engines“.
partner. We have also provided a lot more

this, please get in touch with your contact


0° C

If new pistons and piston rings are fitted The result: Higher oil consumption and
www.ms-motorservice.com
International

into a worn-out cylinder, the piston rings premature wear. information


Further for you at
information canwww.ms-motorservice.com
be obtained directly from and
youron our Technipedia
local
at www.technipedia.info.
International

Worn cylinders
often hit the upper wear edge of the cylin-
der. As a result, the piston rings start to flut- Remedy: Replacement of the cylinder liner
Motorservice partner or at www.ms-motorservice.com
MS Motorservice

ternew
If andpistons
can noand
longer sealrings
piston effectively.
are installed or remachine the
Consequence: cylinder
High bore (drilling,
oil consumption and
© MS©Motorservice

in a worn cylinder, the piston rings often hit honing). wear


premature
Alsoupper
the see “Piston impact
wear edge on cylinder.
of the cylinder head”
As a
and “Worn-out
result, ring
the piston grooves”.
rings start to flutter and Remedy: Replace worn cylinders or rebore
The Motorservice Group is the sales organisation for the global aftermarket
no longer seal properly. cylinders
activities of KSPGGroup
The Motorservice (Kolbenschmidt
is the salesPierburg). It is for
organisation onetheof the leading suppliers
worldwide
See also "Piston impact on the cylinder of engine components
aftermarket activities offor the independent
Rheinmetall aftermarket,
Automotive. including
It is a leading the
supplier
head" and "Dirt in the intake air"
of engine brands
premium components for the independent
KOLBENSCHMIDT, PIERBURGaftermarket. With the
and TRW Engine premium
Components,
brands
as Kolbenschmidt,
well as the BF brand.Pierburg, TRW Engineproduct
Our comprehensive Componentsrange and theour
allows BF brand,
Motorservice
customers offers its
to obtain customers
engine a wide and
components fromcomprehensive
a single source.range of top
quality products from a single source.

ks_50003928.indd 1 11.01.17 16:43


person.

14
Basic information

Table of contents Page


Important information 14
Quality management 14
Rheinmetall Automotive Know-how transfer – professional knowledge from the expert 16
Renowned supplier to the international 1. Engine bearings 18
automotive industry
2. Instructions for using the catalogue 20
Rheinmetall Automotive is the mobility
division of the technology corporation 3. Engine bearing designs 24
­Rheinmetall Group. With its premium 4. Additions to the product range 73

ENGLISH
brands ­Kolbenschmidt, ­Pierburg and
5. List of manufacturers 83
­Motorservice, R­ heinmetall Automotive is
a global leader in the relevant markets for 6. Product range 87
air supply systems, emission control and 7. Piece – Pair/Set/Make/Position 1613
pumps and in the development, manuf- 8. Pair – Set/Make/Position 1699
acture and spare-parts supply of pistons,
9. Set/Make/Position 1717
engine blocks and plain bearings. Low
pollutant emissions, good fuel economy, 10. C
 omparison list: Federal-Mogul & Glyco no. 1755
reliability, quality and safety are the main Kolbenschmidt no.
driving forces behind the innovations of (Federal-Mogul & Glyco no. – Kolbenschmidt no.)
­Rheinmetall Automotive. 11. Claim/Claims form
12. General sales and delivery conditions

Motorservice Group
Quality and service from a single source
The Motorservice Group is the sales
organisation for the worldwide aftermarket
activities of R
­ heinmetall Automotive. It is
a leading supplier of engine components
for the independent aftermarket. With the
premium brands K ­ olbenschmidt, ­Pierburg,
­TRW Engine C ­ omponents and the BF brand,
­Motorservice offers its customers a wide
and comprehensive range of top quality
products from a single source. As a pro-
blem solver for trade and repair shops, the
corporation also offers an extensive service
package. M ­ otorservice customers benefit
from the combined technical know-how of
a large international automotive supplier.

15
Basic information

Know-how
transfer
ENGLISH

Professional knowledge from the experts


Worldwide training Technical information Technical videos
Direct from the manufacturer From practical experience for Professional installation clearly
Each year, around 4,500 mechanics and ­practical use illustrated
engineers benefit from our training courses Our Product Information and Service Knowledge transfer via video: In our
and seminars, which we hold on-site in Information publications, technical videos, you will find practice-orientated
locations across the world or in our training brochures and posters keep you at the fitting instructions and system explana-
centres in Neuenstadt, Dormagen and forefront of the latest technological tions relating to our products.
Asperg (Germany). developments.

News Social media Individual information


Regular information via e-mail Always up to date Especially for our customers
Subscribe online to our free newsletter now We provide extensive information and
and receive regular information about services relating to our wide range of
additions to the product range, technical services: e.g. personalised sales-promo-
publications and much more. ting materials, sales support, technical
support and much more.

16
Basic information

ENGLISH
PI 1575
SI 1210
For technical personnel only!
Page 1/2

Engine bearings with polymer coating Tips and tricks ...


…for correct installation and long service life of the Systemkomponenten
und Service
new short block

für eine fachgerechte Reparatur

• Please note that cylinder heads which • Check the correct operation of the vis- until oil pressure has built up, so that all
may be included in the delivery are not cous fan. bearing points have been supplied with
fully assembled. These must be aligned • Clean water cooler and check for blocka- oil before initial start-up.
with the exhaust manifold or intake • Check for correct function in the oil
manifold and the cylinder head bolts pump, oil pressure control valve, water
must be tightened according to the charge air cooler thoroughly and check pump and vibration damper.
for blockages, it is imperative to replace •
• Clean all attachments thoroughly before this in the case of previous turbocharger -
installation and check for damage. damage. cle manufacturer.
• Clean oil cooler thoroughly and check for • Check engine monitoring instruments for

© MS Motorservice International GmbH – 04/15 EN


blockages, it is imperative to replace this correct operation and replace in case of
in the case of previous engine damage. defects.

www.ms-motorservice.com
• • Never start the engine without oil and
coolant.
• Check connections and intake pipes to • Manually supply (inject) the engine oil
the engine for tightness.
• Check injection system, set start of with oil and crank without injection
delivery according to manufacturer's nozzles (max. 10–15 seconds per
sequence to avoid damage to the starter)

www.ms-motorservice.com

Products in Focus online OnlineShop


Get information on the products Your direct access to our products
online Order at any time. Quick availability check.
Interactive elements, animations and Extensive product search by engine,
video clips provide interesting information vehicle, dimensions etc.
about our products in and around the
engine.

Technipedia Motorservice app


Are you looking for technical Access technical know-how on the
­information relating to engines? move
We share our know-how with you in our Here, you will find the latest information
Technipedia. You can get professional and services relating to our products
knowledge direct from experts here. quickly and easily.

17
Basic information
ENGLISH

1. Engine bearings

Solid bearings Two-component bearings


Reliable endurance performer Tough all-rounder
Produced from a special bronze alloy, Kolbenschmidt two-component bearings
these bushes are primarily used in the are characterised by their high resistance
connecting rod and for the mounting of the to wear and corrosion. Primary applications
camshaft. They are characterised by their of two-component bearings are in low to
high fatigue strength. medium-load bearing positions.

Two-component bearings
For technical information on
products, installation and
Steel-aluminium
running-in:please visit:
www.ms-motorservice.com
Back: Steel
Bearing material: Aluminium

18
Basic information

ENGLISH
Three-component bearings
Withstand the greatest pressure
The sliding layers vary according to the or bonded-coating layers are mainly used
place and type of installation to ensure in high-load engines, primarily as main
a long service life – even under tough bearings and connecting rod bearings.
conditions. Bearings with galvanic, sputter

Three-component Three-component Three-component


bearings bearings bearings

Galvanic Bonded coating Sputter

Back: Steel Back: Steel Back: Steel


Bearing material: Bronze Bearing material: Aluminium or bronze Bearing material: Brass or bronze
Intermediate layer Sliding layer: Bonded coating Intermediate layer (for bronze)
Sliding layer: Galvanic Sliding layer: Sputter

19
Basic information

2. Instructions for using the catalogue

Engine index
Detailed search assistance is The engine designations are listed in
included at the beginning of each ascending alphanumerical order.
manufacturer section.
ENGLISH

Engine Item number

Vehicle index
Detailed search assistance is The vehicles are listed in ascending alpha-
included at the beginning of each numerical order.
manufacturer section.

Vehicle / model series Item number

20
Basic information

Product data
The catalogue pages consist of the informa-
tion blocks shown:

Item number Pictogram line Manufacturer

Manufacturer

ENGLISH
Engine bearing data (mm) Engine line

Engine line

Item number Model year from to Piston families for the listed Compression ratio
(sequential numbering engines. See piston catalogue
for a manufacturer) for details on use.

Cylinder nominal Ø Type of charging* Stroke

Comments Engine number/ Number of Displacement Reference to


identification number cylinders comments

Engine designation with Type of fuel* Number of valves Engine rating from to
type of catalytic converter/
type of pollutant

* see list of abbreviations

21
Basic information

Engine bearing data

Manufacturer
ENGLISH

Bearing design (Standard) shaft diameter (mm)


max.
min.

Housing bore (mm)


max.
min.

Reference to
Materials* Bearing width (mm) Repair grades comments

Bearing position Engine bearing Item no. for


comments bearing pair and
individual part

Installation position: Standard wall Item no. for bearing


thickness (mm) set and thrust washers
= top
= bottom

* see list of abbreviations

22
Basic information

Engine bearing data

Axial clearance Flange span of flanged Comment: Restricted use (model year or
crankshaft (mm) engine number) of product for engine

ENGLISH
No. of bearing pairs
or individual bearings
per engine

Bearing half number Thrust washer thickness (mm) Contents of the


bearing sets per engine
Bearing pair or Repair grade with
bearing set number machining allowance

Thrust washer Thrust washer


inside diameter (mm) outside diameter (mm)

Illustration of an engine bearing

23
Basic information

3. Engine bearing designs

2
3
ENGLISH

6
5

1 Rocker arm bushes (KH-B) 2 Conrod bushes (PL-B) 3 Connecting rod bearing (PL) 4 Main bearing (HL)

5 Flanged bearing (PASS-L) 6 Thrust washers (AS) 7 Camshaft bearing (NW-L)

24
Généralités

FRANÇAIS

FR

Généralités

25
Généralités

Remarques importantes En outre, nous déclinons toute responsabi­ nous parvenir par écrit dans un délai de
Les indications qui figurent dans ce lité quant à l’exactitude des informations 30 jours à compter de la date de survenue
catalogue ont fait l’objet d’un travail et à l’adéquation du produit pour l’usage du dommage.
méticuleux, mais n’engagent pas notre envisagé. Pour s’en assurer, prendre Le délai de prescription concernant la
responsabilité. Nous ne garantissons pas toujours conseil, avant le montage, auprès responsabilité pour vices matériels est
leur exactitude. Il n’est, en particulier, du constructeur ou d’un concessionnaire de 12 mois à compter de la livraison des
pas possible d’exclure des modifications agréé. marchandises.
apportées aux équipements par les con- Les pièces proposées dans le catalogue La responsabilité pour vices matériels
structeurs de véhicules ou de moteurs ne sont pas destinées aux aéronefs. Dans ne s’applique pas si le produit livré a fait
ou encore des modifications des désigna­ le cas de l’utilisation sur des moteurs de l’objet de modifications de la part d’un
tions. Toutes informations relatives marine ou des moteurs stationnaires, tenir tiers ou en cas d’ajout de pièces d’origine
à d’éventuelles erreurs présentes dans le compte du fait que des pièces de moteur tierce, à moins que le vice ne soit pas en
catalogue sont les bienvenues ; ces erreurs différentes (par ex. des pistons) peuvent rapport causal avec la modification. Cette
seront corrigées dans les futures éditions. être utilisées pour une même désignation responsabilité ne s'applique pas non plus
Les noms, les descriptions et les numé- du moteur. quand les prescriptions en vigueur n'ont
rosde véhicules ou de constructeurs, etc., pas été respectées pour le maniement et le
ne sont donnés qu’à des fins de compa- Toute réimpression, reproduction et dupli- montage.
raison. Nous nous réservons le droit de cation, en totalité ou en partie, faite sans Notre garantie ne couvre pas l’usure
modifier à tout moment les spécifications, notre consentement et sans indication normale et les détériorations dues à un
les matériaux et l’aspect de nos produits. de source, est illicite. La présente édition maniement incorrect.
remplace et annule toutes les éditions
FRANÇAIS

Ceci n’affecte en rien la fonction et précédentes du catalogue.


l’application stipulées dans le catalogue. Gestion de l'environnement
Les illustrations, les dessins schémati- Sous réserve de modifications et d’erreurs. Une gestion responsable des ressources,
ques et autres indications sont destinés la protection de notre environnement et
à expliquer et à représenter nos produits le respect de la législation en vigueur
et ne peuvent en aucun cas servir de base Gestion de la qualité sont d'une importance capitale pour une
au montage des pièces, à la définition de Nous sommes certifiés selon ISO 9001 afin collaboration à long terme avec tous nos
l’ensemble de livraison et à la conception. de prouver que notre gestion de la qualité partenaires. C'est pourquoi nous avons
Les références de pièces de rechange satisfait aux exigences des normes interna- décidé de faire certifier notre organisation
d’origine des constructeurs de véhicules tionales en vigueur. conformément à la norme pour systèmes
et de moteurs servent uniquement à des de gestion de l'environnement, ISO 14001.
fins de comparaison. Elles ne constituent Si, en dépit des contrôles effectués tout
pas des désignations de provenance et ne au long du processus de production et
doivent pas être utilisées dans les rapports du rigoureux contrôle final, un défaut de
avec des tiers. Nous déclinons, en particu- matière ou de fabrication apparaît, nous
CERTIFICATE
lier, toute responsabilité pour l’application prenons en charge, durant la période de This is to certify that

Certificate
des listes de correspondances en raison prescription, soit la remise en état du
MS Motorservice International GmbH
Wilhelm-Maybach-Straße 14-18
74196 Neuenstadt
Germany
Standard ISO 9001:2008
Certificate Registr. No. 01 100 4255

des possibles modifications et/ou diffé-


has implemented and maintains an Environmental Management System.

moteur, soit le remplacement du produit


Certificate Holder:

Scope:
Assembling and trading of Engine Parts for the Aftermarket MS Motorservice International GmbH
Wilhelm-Maybach-Str. 14-18
D-74196 Neuenstadt

rences dimensionnelles des constructeurs. défectueux. Les réclamations doivent


including the locations according to annex

Through an audit, documented in a report, it was verified that the management system
fulfills the requirements of the following standard:
Scope: Trading of engine parts for the worldwide aftermarket

ISO 14001 : 2004 + Cor 1 : 2009

Proof has been furnished by means of an audit that the


Certificate registration no. 069998 UM requirements of ISO 9001:2008 are met.
Valid from 2015-12-29
Valid until 2018-09-14
Date of certification 2015-10-28

Validity: The certificate is valid from 2015-11-18 until 2018-09-14.

DQS GmbH

Götz Blechschmidt
Managing Director

2015-12-02
TÜV Rheinland Cert GmbH
Accredited Body: DQS GmbH, August-Schanz-Straße 21, 60433 Frankfurt am Main Am Grauen Stein · 51105 Köln

Installation of Pistons
Step by Step
Vous trouverez davantage d’informations
Test, bore and hone cylinder

Fine-bore the cylinder with fitted main bearing caps. Make a honing
allowance of approx. 0.08 mm (referred to the diameter). Well-honed
cylinder bores should have at least 20 % open graphite veins. Only use the
honing oil recommended by the honing machine manufacturer. The honing
surface
roughness
Rt (value measured by
instrument)
cylinder surface
before running
3–6 µm
Honing tools

• Prehoning: grain size 150 (material removal approx. 0.06 mm referred to the diameter)
• Finish honing: grain size 280 (material removal 0.02 mm referred to the diameter)
• Platform honing: grain size 400–600 (remove profile peaks in a few strokes applying light
contact pressure)
Only for engines with liners

Wet liner:
Clean liner flange seat in crankcase carefully, do not use cutting tools.
Flange seat A must be plane parallel and free of dirt. Treat sealing rings
carefully with assembly grease (e.g oil). It must be possible to introduce
techniques sur notre site.
angle should be between 40–80 degrees. Provide for a certain cylinder • Honing and brushing: use hones of grain size 120, 150, 180 for honing. For block engines the cylinder liner without great effort; avoid by all means hard impacts

Pistonrings
Rings
Ra (value measured by 0.4–0.8 µm

Piston
surface roughness to ensure perfect adherence of the oil film: there are (grey casting) bond 5-7, for liner (centrifugal casting) bond 5 max. Material removal: or moving of the liner. The liner projecting length B should be as
instrument) standard honing plateau honing Correct flange seat
three current measuring methods as outlined in Table. between 0.03 and 0.05 mm referred to the diameter. Using honing brushes removes specified by the engine manufacturer (e.g. 0.05 – 0.1 mm).
R3Z (diagram evaluation) 4–7 µm
peaks that occur on the surface of the cylinder during the final honing operation.
This requires at least ten strokes and the use of honing oil. To achieve optimum results, Dry liner:
the rotation direction of the honing machine should be reversed after half of the Apply anti-seize agent to the outside diameter of the cylinder liner.
processing time. The honing brushes reduce cylinder diameter by between 0.001 and a Dry liners have typically an overdimension compared with the cylinder
maximum of 0.01 mm. block, having to be pressed in (interference fit). The edge chamfer C in

Function and Design


Function design
Preparing

• Check the cylinder diameter at top, centre and bottom as well as in longitudinal and the case should correspond to radius D at the cylinder liner.
transversal direction (90° off-set). Incorrect flange seat
hone brushing

www.ms-motorservice.com
nominal cylinder tolerrance
dimension range to be complied with
Attention Ø 30–50 mm 0.011 mm
Clean cylinder bore and cylinder blocks after honing Ø 50–80 mm 0.013 mm
(e.g. ultrasonic cleaning). Ø 80–120 mm 0.015 mm
Ø 120–180 mm 0.018 mm

Incorrect reconditioning Maintenance faults


Piston impact on cylinder head Worn-out ring grooves
If the sealing surface of an engine block is The result: High oil consumption and high Dirt that reaches the combustion The result: High oil consumption and poor
reconditioned and a piston with standard cylinder wear (see also “Fuel Flooding”). chamber settles in the ring grooves where performance.

Incorrect reconditioning Maintenance faultsand at the flanks of the piston ring. This
compression height fitted, this may cause it causes abrasive wear in the ring grooves
mechanical impact by the piston on the
cylinder head in the case of diesel engines.
Remedy: Compliance with the correct
piston protrusion; use of correct cylinder
General results in excessive ring height clearance
Remedy: Regular air filter main-tenance,
especially in very dusty areas.
Assembly of piston and conrod Placing the piston into the cylinder bore
Piston impact
The same occurs on the
if cylinder cylinder
head gaskets with head
head gaskets. Dirtconsequently
and in the intake air
to a deterioration of the
the wrong thickness are fi tted. Due to these guidance of the piston rings in the ring
If theim-pacts,
hard sealing area of an engine
the piston block
rings start is
to flutter Consequence: High oil consumption and Dirt that reaches
grooves. The ringsthe combustion
will chamber
become bent during Consequence: High oil consumption and
reconditioned and a piston
and vibrate, dislodging withcation
the lubri standard
film high cylinder wear (see also "Fuel flooding") KOLBENSCHMIDT settles
use uses
and thepreservatives
instart ring
to grooves
flutter. that
where
If the rings do
itare
causes poor performance Check conrods for deformation and torsion using a suitable Floating pins: Assembly of conrod with fixed pin: Clean the cylinder block carefully after Anodized pistons:
compression height fitted,
and as a consequence sealing this
is may cause
no longer abrasive
not affect theseverely
engineworn wear in
oil; at the
it the ringneces
sides,
is not grooves
they saryand
can at the
break. testing instrument before installing them. The maximum Fix the pin, use the enclosed retainer rings and avoid excessive The conrod eye bore must provide for an overlap with making sure that all sliding surfaces are free For pistons with anodized piston crown, the crown must
mechanical
effectively. impact by the piston on the Remedy: Compliance with the correct piston piston ring flanks. This results in excessive Remedy: Regular air filter maintenance, tolerance must not exceed 0.02 mm per 100 mm. Put the from dirt and well oiled.
therefore to clean the pistons. Data about compression which might produce permanent deformation. Please respect to the pin 0.02–0.04 mm. Heat the conrod to not be turned to adjust the gap dimension. These pistons
cylinder head in the case of diesel engines. protrusion, use of the correct cylinder head ring height clearance and consequently to particularly in dusty areas
Ring
The same joint
occursclearance
if cylinder head too small gaskets
gaskets piston diameter, assemblyofclearance
a deterioration the guidanceand of the piston piston and the conrod in place in use a special tool. Turn the rings slightly to make sure that they 280–320 °C (no bare flame!). After oiling the pin and Compress the piston ring using a squeezer are recognizable by the black colour of the crown surface.
with the wrong thickness are fitted. Due to rings in (e.g.
assembly direction the ring grooves.
arrow) areThetorings
be will accordance with the assembly have safely engaged in the grooves. Place the joint of the retainer allowing it to cool, introduce it swiftly into the eye in order to allow the piston to slide smoothly Certain piston types with anodized crowns have, besides
The piston
these hard ring joint the
impacts, clearance
piston is compa-
rings start to The result: Premature piston ring wear, become bent during use and start to flutter. direction. Next the conrod eye
found on the piston crown. Be aware that the in running direction of the piston. using a device. Then check the correct piston fit using into the cylinder bore. Measure the gap the standard piston, pistons with reduced compression
rable to
flutter theno
and valve
longer clearance. When the
seal properly. piston seizure and high oil consumption. If the rings are severely worn at the sides,
parts are warmed up, the components are cylinder diameter comprises the piston skirt may take up the gudgeon pin. a testing instrument. dimension in the case of diesel engines and height for adjustment of the gap. In most cases,
they can break.
thermally heated which results in a change Remedy: It is essential that the minimum diameter plus assembly clearance. Slide the oiled pin gently into the abide by all means by the manufacturer´s the compression piston dimension is staged from
in length. As long as the machine is cold, joint clearances are complied with – a reduc-
For pistons with a graphite layer, deduct pin bores of the piston and the instructions. 0.2–0.6 mm.
Piston ring joint
the joint clearance preventsclearance
the pistons intoo small
tion of the joint clearance by the repair shop
eye of the conrod. Avoid any jerky
0.015–0.02 mm layer thickness from the
100° C

the cylinder from being jammed when the is not permitted.


Installation

Attention
The pistonis ring
hot.joint
If theclearance is Consequence: Premature piston ring wear, dimension measured movement.
Jammedtopiston get the stamped-on
0° C

machine
comparable to the
joint clearance
valve clearance.
is too
Warming piston seizure and high oil consumption
rings If shaped pins are specified, please use.
small when the machine is cold, there will skirt dimension. In the case of pistons
100° C
up
be the parts causes
an excessive ratethermal
of wear expansion
on the piston of Piston rings must be able to rotate freely in The result: Piston seizure, high wear and
0° C the
ring,components
sealing problems and a change
and enginein length.
failure Remedy: It is essential that the minimum graphitized according to the screen printing
their ring grooves during operation (excep- high oil consumption.
The
couldjoint clearance
occur when the when the machine
machine is hot. is joint clearances are complied with – process, measure the skirtengines).
tion: two-stroke diameter only
If the at rings
piston
cold ensures that the piston rings in the a reduction of the joint clearance by the
100° C
the specified are
measuring
blocked bypoints – smallorareas
carbon deposits dirt in Remedy: Regular air filter maintenance and
25–40 µm
cylinder will not get stuck when the
0° C
Asymmetric piston wear patternrepair shop is not permitted
machine is hot. If the joint clearance is too
the ring
without graphite grooves they are no longer able to
layer. the use of engine oil with the prescribed oil

Les contenus de la boutique en ligne exi-


small whenconnecting
the machine is cold, there will
Blocked
seal properlypiston rings
and will not wear uniformly. specification for the engine.
Deformed rods, which often The result: High wear, ring fractures and If the rings are clamped in the grooves, the
be highaspiston ringof wear,
enginesealing
failure,problems
100° C

occur a result can excessive oil consumption. Piston rings


sealing effectmust
is nobe able to
longer rotate freely
warranted. This Consequence: Piston seizure, high wear and
0° C
and
cause engine damage
the piston whenan
to have the engine is
incorrect hot.
atti- in their aring
causes grooves
blow-by during operation
of combustion gases on high oil consumption
tude in the cylinder. The piston rings con- Remedy: Check the connecting rod (exception: two-stroke
compression rings, andengines).
results in Ifthe
thepenet- measuring points
sequently take on an elliptical form and no for deformation and torsion prior to pistonof
ration rings are the
oil into blocked by carbon
combustion deposits
chamber Remedy: Regular air filter maintenance
Asymmetric
longer rotate in thepiston wear
piston. This pattern
results in installing it. or dirt
on in the ring grooves, they are no
oil rings. and use of engine oil with the right oil
uneven wear and piston ring fluttering. longer able to seal properly and will not specification for the engine
Bent connecting rods, which often occur as Consequence: High level of wear, ring wear uniformly. It the rings get stuck in the
a result of engine damage, cause the piston fractures and excessive oil consumption
Abnormal combustion
grooves, the sealing effect is no longer
TIPS & INFOS
SERVICE

to run at an angle in the cylinder. The piston guaranteed. This causes a blow-by of
rings consequently take on an elliptical Remedy: Check the connecting rod for

Piston damage –
combustion gases on compression rings,
form and no longer rotate in the piston. distortion and twisting before installing it Knocking combustion and glow ignition
and results in the passage of oil into the
This results in uneven wear and ring flutter. combustion chamber on oil rings.
Piston ring assembly Engine trial run After running in
Knocking combustion or glow ignitions The result: Piston seizure, loss of engine
result in excessive pressure peaks in the power and/or high oil consumption.
cylinder as well as high mechanical stress
© MS Motorservice International GmbH – 50 003842-02 – 02/15 EN

Remedy: Use of high-grade fuels.


Combustion defaults
of the parts. The piston rings start to flut-

recognising and rectifying


Installation of worn-out parts ter and can break. On moly-bdenumplated

stent également sous forme de catalogue


rings, the moly-bdenum layer can break
KOLBENSCHMIDT pistons are available ready for installation. It is not necessary to Do not start the newly overhauled engine until it is assembled The quickly flowing hot oil will Information about our product range can be found in our
Knocking
away. combustion and glow ignition
Out-of-round cylinders assemble the rings which could lead to excessive strain. If you want to install a completely with all fittings and filled with oil and cooling water. clean the engine from all foreign catalogue “Pistons and Components”.
Knocking combustion and please
glow ignition Consequence:
tool. BePiston seizure,
that loss of
Installing worn parts When machining the cylinder bores, it is
essential to make sure that the geometry
The result: Poor performance, excessive
oil consumption and engine failures.
KOLBENSCHMIDT ring set in a used piston,
causes excessive pressure peaks in the
the assembly directioncylinder
of some andring types is identified
use a special aware
engine power and/or high oil consumption
with “TOP” (“TOP” should
Ensure that the engine starts at the very first starting attempt since
the first fuel revolutions are subject to critical lubricating conditions
matter that may still adhere after
the overhaul. These particles will
Further information can be obtained directly from your local
high mechanical stress on the Motorservice partner or at www.ms-motorservice.com
To
p is perfect. The piston rings can still seal
Out-of-round cylinders Fuel
face to the piston crown).
parts. flooding
Napier
The rings
piston and
rings oiltocontrol
start flutter andrings should
Remedy: be Use installed
of high-gradesuch
fuels and decisive for the subsequent operating behaviour of the engine. collect in the engine oil and oil
slightly oval cylinders. However, sealing Remedy: Observe the tightening specifi-
can break.
that the oil is scraped down Withbottom
to the molybdenum-coated
skirt end.rings,
See to The
it that theHigh
joint
ringends of wear, After warm running of the engine, check it again for leaks, ignition, filter. A distance of 50 km is
www.ms-motorservice.com

becomes more difficult with out- of-rounds cations for the cylinder head or exclude The oil film is washed off due to incomplete result: and cylinder
When machining the cylinder bores, it is Consequence: Poor performance, excessive the molybdenum layer can break away.
of the 3rdto
ormake
4th order. These out-of-rounds during cylinder machining. the spiral expander in combustion
the oil control
of the ring arefuel
in-jected always locatedhigh
or to exces- opposite to the ring
oil consumption. valve clearance, etc. Then start running the engine in on the test sufficient for most of all dirt
essential sure that theare often is
geometry oil consumption and engine damage
caused by tension stressing sive injected
joint. In the case of tripartite fuel. This
oil rings causes mixed
(expander fric- with lateral segments), the
spring bench or in the vehicle. Operate the engine at not more than two- particles to accumulate. Do not
perfect. Piston rings can stillfrom
seal the cylin-
slightly Out-of-rounds: tion or even dry friction of the piston in the Remedy: Correct function and setting of
p

der head bolts. The crescent-shaped gap


To

oval cylinders. Remedy: Observe cylinder head tightening Sliding friction


segment joints shouldcylinder.
be off-set by about 120°. thirds of its nominal speed at moderate load changes; later on, the operate the engine for more than
caused by out-of-roundness between the
However, sealing becomes difficult for 3rd specifications or eliminate out-of-roundness
The metal parts rub against each the fuel system.
number of revolutions may be increased gradually. 500 km with the first oil fill. The Motorservice Group is the sales organisation for the global aftermarket activities of
piston ring and the cylinder will result in other without a protective oil film.
and 4th order out-of-roundness. These
leakages.
during cylinder machining
Fuel flooding KSPG (Kolbenschmidt Pierburg). It is one of the leading suppliers of engine components for
often occur due to tensile stresses from the
cylinder head bolts. The crescent-shaped Out-of-roundness: the independent aftermarket, including the premium brands KOLBENSCHMIDT, PIERBURG and
The oil film is washed off due to incomplete Consequence: High ring and cylinder wear,
gaps caused by out-of-roundness between
3rd order 4th order combustion of the injected fuel or too much high oil consumption TRW Engine Components, as well as the BF brand. Our comprehensive product range allows
the piston ring and cylinder will result in Mixed friction
Trial run

leaks.
injected fuel. This causes mixed or dry our customers to obtain engine components from a single source.
friction of the piston in the cylinder. The Remedy: Correct function and adjustment

électronique sur le « Motorservice Product


Ring joint clearance too great Liquid friction
metal parts rub against one another. of the fuel system
An excessive joint clearance on the piston Remedy:
3rd order Replace
4thworn-out
order pistons and
rings appears after a long running period cylinders.
and high wear on the cylinder and piston
Piston
rings. The ring joint clearance
joint clearance is too great if ittoo great
has doubled its size compared to its new
An excessive joint clearance on the piston Remedy: Replace worn pistons and Mixed friction
condition. Clearance exten-sions of up to
rings appears after a long service life and cylinders
0.3 mm are irrelevant. They contribute
high wear on the cylinders and piston rings.
01/15(122016)

neither to a loss of engine power nor to


100° C
The joint clearance is too great if it has
excessive oil consumption. Slightly en-
EN

0° C doubled its size compared to its new


larged piston ring joint clearances are often
– EN ––02/15

condition. Increases in clearance of up to d


over-estimated. On this topic, also see
100° C
0.3 mm are negligible. They contribute
“Ring joint clearance too small”.
003 928-02

100°
0° C
C
neither to a notable loss of engine power
nor to high oil consumption. The
– 50928-02

significance of a slightly enlarged piston


0° C

d
ring joint clearance is often over-estimated. Further details on this subject can be found in our brochure
– 50 003

100° C
Worn-out
See also "Pistoncylinders
ring joint clearance too Details
"Pistonon thisfor
Rings subject can be found
Combustion in our brochure
Engines".
GmbHGmbH
www.ms-motorservice.com

small". „Piston Rings


Or ask your forMotorservice
local Combustion Engines“.
partner. We have also provided a lot more

Disc ». Contactez votre correspondant.


0° C

If new pistons and piston rings are fitted The result: Higher oil consumption and
www.ms-motorservice.com
International

into a worn-out cylinder, the piston rings premature wear. information


Further for you at
information canwww.ms-motorservice.com
be obtained directly from and
youron our Technipedia
local
at www.technipedia.info.
International

Worn cylinders
often hit the upper wear edge of the cylin-
der. As a result, the piston rings start to flut- Remedy: Replacement of the cylinder liner
Motorservice partner or at www.ms-motorservice.com
MS Motorservice

ternew
If andpistons
can noand
longer sealrings
piston effectively.
are installed or remachine the
Consequence: cylinder
High bore (drilling,
oil consumption and
© MS©Motorservice

in a worn cylinder, the piston rings often hit honing). wear


premature
Alsoupper
the see “Piston impact
wear edge on cylinder.
of the cylinder head”
As a
and “Worn-out
result, ring
the piston grooves”.
rings start to flutter and Remedy: Replace worn cylinders or rebore
The Motorservice Group is the sales organisation for the global aftermarket
no longer seal properly. cylinders
activities of KSPGGroup
The Motorservice (Kolbenschmidt
is the salesPierburg). It is for
organisation onetheof the leading suppliers
worldwide
See also "Piston impact on the cylinder of engine components
aftermarket activities offor the independent
Rheinmetall aftermarket,
Automotive. including
It is a leading the
supplier
head" and "Dirt in the intake air"
of engine brands
premium components for the independent
KOLBENSCHMIDT, PIERBURGaftermarket. With the
and TRW Engine premium
Components,
brands
as Kolbenschmidt,
well as the BF brand.Pierburg, TRW Engineproduct
Our comprehensive Componentsrange and theour
allows BF brand,
Motorservice
customers offers its
to obtain customers
engine a wide and
components fromcomprehensive
a single source.range of top
quality products from a single source.

ks_50003928.indd 1 11.01.17 16:43

26
Généralités

Table des matières Page


Remarques importantes 26

Rheinmetall Automotive Gestion de la qualité 26


Équipementier renommé de l‘industrie Transfert de savoir-faire – Compétence des experts 28
automobile internationale 1. Coussinets 30
Rheinmetall Automotive est la sec-
2. Précisions sur l’utilisation du catalogue 32
tion Mobilité du groupe technologique
­Rheinmetall. Avec ses marques haut 3. Types de coussinets dans le moteur 36
de gamme ­Kolbenschmidt, ­Pierburg et 4. Compléments de la gamme 73
­Motorservice, Rheinmetall Automotive se
5. Tableau des constructeurs 83
situe mondialement en tête des mar-
chés respectifs dans les domaines de 6. Gamme de produits 87
l’alimentation en air, de la réduction des 7.  ièce détachée – Paire/jeu
P 1613
émissions nocives et des pompes ainsi que (Piece – Pair/Set/Make/Position)
dans le développement, la fabrication et la 8. Paire – Jeu (Pair – Set/Make/Position) 1699
fourniture de pistons, de blocs-moteurs et
9. Jeu (Set/Make/Position) 1717
de coussinets. Dans le cadre des inno-
vations de Rheinmetall Automotive, les 10. L iste de correspondances N° Federal Mogul & Glyco 1755
objectifs de motivation primordiaux sont N° Kolbenschmidt
la réduction des émissions de polluants et (Federal-Mogul & Glyco-No. – Kolbenschmidt No.)

FRANÇAIS
celle de la consommation de carburant, la 11. Réclamation/formulaire de réclamation
fiabilité, la qualité et la sécurité.
12. Conditions de vente et de livraison

Groupe Motorservice
Qualité et service auprès d‘un unique
fournisseur
Le groupe Motorservice est l‘organisation
commerciale chargée des activités
aftermarket mondiales de Rheinmetall
­Automotive. C‘est l’un des premiers
fournisseurs de composants moteurs
pour le marché indépendant des pièces
de rechange. Avec les marques haut
de gamme ­Kolbenschmidt, ­Pierburg,
TRW ­Engine ­Components ainsi que la
marque BF, ­Motorservice propose à ses
clients une gamme large et profonde, de
très grande qualité, auprès d‘un unique
fournisseur. Il répond également aux
problèmes des commerces et des garages
avec un éventail exhaustif de prestations
de service. Ainsi, les clients de Motorser-
vice bénéficient du savoir-faire technique
concentré d‘un grand équipementier auto-
mobile international.

27
Généralités

Transfert de
savoir-faire
FRANÇAIS

La compétence d'un expert


Formations dans le monde Informations techniques Vidéos techniques
entier Des informations issues de la Le montage professionnel expliqué
En direct du fabricant pratique pour la pratique de façon claire
Tous les ans, environ 4 500 mécaniciens et Avec nos Product Information, Service Transmission des connaissances par
techniciens profitent de nos formations et Information, brochures techniques et vidéo : dans nos vidéos, vous trouverez des
des séminaires que nous organisons sur posters, vous êtes à chaque instant à la instructions de montage axées sur la
place, dans le monde entier, ou dans nos pointe de la technique. pratique et des explications concernant
centres de formation de Neuenstadt, nos produits.
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28
Généralités

PI 1575
SI 1210
For technical personnel only!
Page 1/2

Engine bearings with polymer coating Tips and tricks ...


…for correct installation and long service life of the Systemkomponenten
und Service
new short block

für eine fachgerechte Reparatur

• Please note that cylinder heads which • Check the correct operation of the vis- until oil pressure has built up, so that all
may be included in the delivery are not cous fan. bearing points have been supplied with
fully assembled. These must be aligned • Clean water cooler and check for blocka- oil before initial start-up.
with the exhaust manifold or intake • Check for correct function in the oil
manifold and the cylinder head bolts pump, oil pressure control valve, water
must be tightened according to the charge air cooler thoroughly and check pump and vibration damper.
for blockages, it is imperative to replace •
• Clean all attachments thoroughly before this in the case of previous turbocharger -
installation and check for damage. damage. cle manufacturer.
• Clean oil cooler thoroughly and check for • Check engine monitoring instruments for

© MS Motorservice International GmbH – 04/15 EN


blockages, it is imperative to replace this correct operation and replace in case of
in the case of previous engine damage. defects.

www.ms-motorservice.com
• • Never start the engine without oil and
coolant.
• Check connections and intake pipes to • Manually supply (inject) the engine oil
the engine for tightness.
• Check injection system, set start of with oil and crank without injection
delivery according to manufacturer's nozzles (max. 10–15 seconds per
sequence to avoid damage to the starter)

FRANÇAIS
www.ms-motorservice.com

Pleins feux sur les produits Boutique en ligne


en ligne Votre accès direct à nos produits
Obtenir des informations en ligne Commande 24 h sur 24. Contrôle rapide de
sur nos produits la disponibilité. Recherche produits
Au travers d'éléments interactifs, exhaustive par moteur, véhicule,
d'animations et de clips vidéo, apprenez dimensions, etc.
tout ce qu'il faut savoir sur nos produits
pour le moteur.

Technipedia L'appli Motorservice


Vous cherchez des informations sur Un accès mobile à notre savoir-faire
un moteur ? technique
Avec Technipedia, nous vous offrons un Vous y trouverez rapidement et facilement
accès à notre savoir-faire. Vous y trouverez les informations et les services les plus
les connaissances techniques de nos à jour relatifs à nos produits.
experts directement.

29
Généralités
FRANÇAIS

1. Coussinets

Coussinets massifs Coussinets à deux composants


Fiables et endurants Polyvalents et robustes
Ces bagues composées d’un alliage de Les coussinets à deux composants
bronze spécial sont utilisées principale­ Kolbenschmidt se distinguent par leur
ment dans les bielles et les paliers d’arbres haute résistance à l’usure et à la corrosion.
à cames. Elles se distinguent par leur Les coussinets à deux composants sont
grande résistance à la fatigue. surtout utilisés pour les paliers soumis
à des contraintes moyennes.

Coussinet à deux
composants
Vous trouverez des informations
techniques sur les produits,
Acier-aluminium
le montage et le rodagesous :
www.ms-motorservice.com
Dos : acier
Matériau d'appui : aluminium

30
Généralités

FRANÇAIS
Coussinets à trois composants
À l’épreuve des pressions extrêmes
Les couches de glissement différentes Les coussinets dotés d’une couche galvani­
selon le lieu et le type d’utilisation sée, sputter ou de vernis antifriction sont
garantissent une longue durée de vie, surtout utilisés dans les moteurs fortement
même sous des conditions très difficiles. sollicités. Ils servent avant tout de coussi­
nets de ligne et de coussinets de bielle.

Coussinet à trois Coussinet à trois Coussinet à trois


composants composants composants

Galvanisation Vernis antifriction Sputter

Dos : acier Dos : acier Dos : acier


Matériau d'appui : bronze Matériau d'appui : aluminium ou bronze Matériau d'appui : laiton ou bronze
Couche intermédiaire Revêtement de roulement : vernis antifriction Couche intermédiaire (dans le cas du bronze)
Revêtement de roulement : galvanisation Revêtement de roulement : sputter

31
Généralités

2. Précisions sur l’utilisation du catalogue

Index des moteurs


Une aide à la recherche détaillée Les désignations des moteurs sont
figure au début de chaque section ­classées en ordre alphanumérique.
consacrée à un constructeur.
FRANÇAIS

Moteur N° de position

Index des véhicules


Une aide à la recherche détaillée Les véhicules sont classés en ordre
figure au début de chaque section ­alphanumérique.
consacrée à un constructeur.

Véhicule / série de modéles N° de position

32
Généralités

Données sur les produits


Les pages du catalogue sont composées des
blocs d’information représentés ci-après :

N° de position Ligne consacrée aux pictogrammes Constructeur

Constructeur

FRANÇAIS
Données sur les coussinets (mm) Ligne consacrée au moteur

Ligne consacrée au moteur

N° de position Année de construction de à Familles de pistons pour les moteurs Taux de compression
(numérotation continue indiqués. Pour les détails d’utilisation,
pour chaque constructeur) voir le catalogue de pistons.

Ø nominal des cylindres Type d'alimentation du moteur* Course

Observations Numéro du moteur/ Nombre de cylindres Cylindrée Renvoi à des


numéro de série observations

Désignation du moteur avec type Type de carburant* Nombre de soupapes Puissance de à


de catalyseur/catégorie de pollution

* voir liste des abréviations

33
Généralités

Données sur les coussinets

Constructeur

Type de coussinet Diamètre de l’arbre (standard) (mm)


max.
min.
FRANÇAIS

Alésage du boîtier (mm)


max.
min.

Renvoi à des
Matériaux* Largeur du coussinet (mm) Cotes de réparation observations

Position du coussinet Observations N° d’article de la paire


sur le coussinet de coussinets et de la
pièce détachée

Position de montage : Épaisseur de la N° d’article du jeu de coussinets


paroi standard et des rondelles de guidage
= en haut
(mm)
= en bas

* voir liste des abréviations

34
Généralités

Données sur les coussinets

Jeu axial Distance entre faces Observation : restriction (année de construction


du vilebrequin (mm) ou numéro du moteur) du produit/moteur

Nombre de paires de
coussinets ou de coussinets
simples par moteur

N° du demi-coussinet Épaisseur de la rondelle Contenu des jeux de


de guidage (mm) coussinets par moteur
N° de la paire de coussinets
Cote de réparation avec
ou du jeu de coussinets
surépaisseur d'usinage

FRANÇAIS
Diamètre intérieur des Diamètre extérieur des
rondelles de guidage (mm) rondelles de guidage (mm)

Représentation d’un coussinet

35
Généralités

3. Types de coussinets dans le moteur

2
3
FRANÇAIS

6
5

1 Bagues de culbuteur (KH-B) 2 Bagues de bielle (PL-B) 3 Coussinets de bielle (PL) 4 Coussinets de ligne (HL)

5 Coussinets de butée (PASS-L) 6 Rondelles de guidage (AS) 7 Coussinets d'arbre à cames


(NW-L)

36
Fundamentos

ESPAÑOL

ES

Fundamentos

37
Fundamentos

Nota importante la idoneidad de los productos para la comunicar por escrito en un plazo de
Las informaciones y datos recopilados en fina­li­dad prevista. Para asegurarse de 30 días tras presentarse el fallo.
este catálogo han sido elaborados conci­ ello aconsejamos solicitar asesoramiento El plazo límite para las reclamaciones por
enzudamente, pero no son vincu­lan­tes. especializado al fabricante o a un taller defectos es de 12 meses, contados a partir
Todas las reclamaciones de indemnización autorizado por este antes de realizar el de la fecha de envío del producto.
relacionadas con ellos están excluidas. En montaje. El derecho de reclamaciones por defec­
particular, no podemos Las piezas ofrecidas en el catálogo no tos quedará sin vigencia si el producto
descartar modificaciones al equipamiento están destinadas para el uso en aeronaves. suministrado es modificado por terceros
hechas por parte de los fabricantes de En caso de aplicación en motores marinos o mediante el montaje de piezas de otros
vehículos o de motores, así como modi­ o motores estacionarios hay que tener en fabricantes, salvo que no haya una relación
ficaciones en las designaciones. Cualquier cuenta que, con la misma denominación causal entre el defecto y la modificación
notificación sobre posibles errores en el de motor, quizá sean necesarias piezas efectuada. El derecho a reclamación por
catálogo será bienvenida, corrigiéndose motrices diferentes (p. ej., pistones). defectos quedará, asimismo, sin vigencia
estos en ediciones posteriores. Los nom­ si no se cumplen las prescripciones vigen­
bres, las designa­ciones y las indica­cio­nes La copia, el plagio, la reproducción total tes para el manejo y el montaje.
de números de vehículos o de fabricantes, o parcial requieren nuestra autorización Nuestra garantía no cubre el desgaste nor­
entre otros, solo tienen un fin comparativo. escrita, asimismo, deberá indicarse la mal ni los daños resultantes de manejos
Queda reservado el derecho a modificar en fuente de origen. La presente versión de inadecuados.
cualquier momento las especificaciones, este catálogo sustituye y anula todas las
los materiales y la apariencia de nuestros versiones anteriores.
productos. Gestión medioambiental
Nos reservamos el derecho a efectuar Para nosotros es muy importante apro­
La función y el propósito indicados en modificaciones y no nos responsabili­ ve­char los recursos naturales de forma
el catálogo no se ven afectados. Las zamos de los errores. responsable, proteger el medio ambiente
ilustraciones, los esquemas y otros datos y cumplir todas las obligaciones legales
se entienden a modo de explicación y relevantes para establecer una colabora­
representación, y por tanto no se pueden Gestión de calidad ción a largo plazo con todos nuestros
usar como base para el montaje, para el Como prueba de que nuestra gestión de socios. Estos son los motivos que nos lle­
volumen suministrado o el diseño. Los calidad cumple los requisitos de las nor­ varon a cumplir con la norma para sistemas
datos sobre números de pieza de repuesto mas internacionales pertinentes, estamos de gestión medioambiental ISO 14001 y a
originales de los fabricantes de vehículos certificados según ISO 9001. obtener el certificado correspondiente.
y motores son solo válidos a modo de
ESPAÑOL

comparación. No son designaciones de Si en algún caso, a pesar de los controles


procedencia y no deben usarse frente a ter­ realizados constantemente durante el pro­
ceros. No nos hacemos responsables por el ceso de producción y del minucioso control
uso de las listas comparativas, en especial, final, se presentara un fallo de material o
CERTIFICATE
debido a posibles modificaciones y/o dife­ de fabricación, naturalmente nos haremos This is to certify that

Certificate
rencias de dimensiones de los fabricantes cargo de la reparación del
MS Motorservice International GmbH
Wilhelm-Maybach-Straße 14-18
74196 Neuenstadt
Germany
Standard ISO 9001:2008
Certificate Registr. No. 01 100 4255

individuales.
has implemented and maintains an Environmental Management System.

motor o sustituiremos el producto defec­


Certificate Holder:

Scope:
Assembling and trading of Engine Parts for the Aftermarket MS Motorservice International GmbH
Wilhelm-Maybach-Str. 14-18
D-74196 Neuenstadt

Además, no asumimos ninguna responsa­ tuoso dentro del plazo límite estipulado.
including the locations according to annex

Through an audit, documented in a report, it was verified that the management system
fulfills the requirements of the following standard:
Scope: Trading of engine parts for the worldwide aftermarket

ISO 14001 : 2004 + Cor 1 : 2009

bi­lidad por la exactitud de los datos ni por Este tipo de reclamaciones se nos deben
Proof has been furnished by means of an audit that the
Certificate registration no. 069998 UM requirements of ISO 9001:2008 are met.
Valid from 2015-12-29
Valid until 2018-09-14
Date of certification 2015-10-28

Validity: The certificate is valid from 2015-11-18 until 2018-09-14.

DQS GmbH

Götz Blechschmidt
Managing Director

2015-12-02
TÜV Rheinland Cert GmbH
Accredited Body: DQS GmbH, August-Schanz-Straße 21, 60433 Frankfurt am Main Am Grauen Stein · 51105 Köln

Installation of Pistons
Step by Step
Podrá encontrar más información técnica
Test, bore and hone cylinder

Fine-bore the cylinder with fitted main bearing caps. Make a honing
allowance of approx. 0.08 mm (referred to the diameter). Well-honed
cylinder bores should have at least 20 % open graphite veins. Only use the
honing oil recommended by the honing machine manufacturer. The honing
surface
roughness
Rt (value measured by
instrument)
cylinder surface
before running
3–6 µm
Honing tools

• Prehoning: grain size 150 (material removal approx. 0.06 mm referred to the diameter)
• Finish honing: grain size 280 (material removal 0.02 mm referred to the diameter)
• Platform honing: grain size 400–600 (remove profile peaks in a few strokes applying light
contact pressure)
Only for engines with liners

Wet liner:
Clean liner flange seat in crankcase carefully, do not use cutting tools.
Flange seat A must be plane parallel and free of dirt. Treat sealing rings
carefully with assembly grease (e.g oil). It must be possible to introduce
en nuestra página web.
angle should be between 40–80 degrees. Provide for a certain cylinder • Honing and brushing: use hones of grain size 120, 150, 180 for honing. For block engines the cylinder liner without great effort; avoid by all means hard impacts

Pistonrings
Rings
Ra (value measured by 0.4–0.8 µm

Piston
surface roughness to ensure perfect adherence of the oil film: there are (grey casting) bond 5-7, for liner (centrifugal casting) bond 5 max. Material removal: or moving of the liner. The liner projecting length B should be as
instrument) standard honing plateau honing Correct flange seat
three current measuring methods as outlined in Table. between 0.03 and 0.05 mm referred to the diameter. Using honing brushes removes specified by the engine manufacturer (e.g. 0.05 – 0.1 mm).
R3Z (diagram evaluation) 4–7 µm
peaks that occur on the surface of the cylinder during the final honing operation.
This requires at least ten strokes and the use of honing oil. To achieve optimum results, Dry liner:
the rotation direction of the honing machine should be reversed after half of the Apply anti-seize agent to the outside diameter of the cylinder liner.
processing time. The honing brushes reduce cylinder diameter by between 0.001 and a Dry liners have typically an overdimension compared with the cylinder
maximum of 0.01 mm. block, having to be pressed in (interference fit). The edge chamfer C in

Function and Design


Function design
Preparing

• Check the cylinder diameter at top, centre and bottom as well as in longitudinal and the case should correspond to radius D at the cylinder liner.
transversal direction (90° off-set). Incorrect flange seat
hone brushing

www.ms-motorservice.com
nominal cylinder tolerrance
dimension range to be complied with
Attention Ø 30–50 mm 0.011 mm
Clean cylinder bore an