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Purpose
Compresses air molecules before
combustion.
Transfers the pressure of expanding
gases to the crankshaft, forcing it to
turn.
On a 2 stroke engine it acts as a
valve by covering and uncovering
cylinder intake and/or exhaust ports.
Location
Inside each cylinder
Crown
Top of the
Piston.
Various
shapes aid
in creating
air
turbulence
for
combustion
Bosses
Ring
Grooves
Skirt
Part of the
piston
Confines
between the
each ring
used to seal the first ring
groove above
the space
between the the piston pin
cylinder wall hole, and the
bottom of the
and piston
piston.
Reinforced
openings in the
piston body.
Provide a means
to connect the
piston to the
connecting rod.
Ring Lands
Oil Drain
Passages
Trunk Type
Unit
construction
Skirt is long
enough to
take up side
thrust without
scoring
(scratching)
the liner.
Crosshead Type:
A two piece unit with a crown that can
withstand the high heat and pressure of a
turbocharged engine. The crown and skirt
are held together by the piston pin. The
downward load on the crown is directed
onto the piston pin through a large bearing.
Skirt is specifically designed to absorb side
thrust. The skirt has less thermal distortion
than the crown, and free of downward
thrust.
It guides the piston in the liner, takes up
side thrust, and carries oil rings. The
crown is subject to only a slight amount of
side thrust.
Shaker:
Circulation:
Oil Jet:
Spray:
Piston Rings
Location
Rings fit in grooves around the piston crown and /or skirt.
Number and location will vary with type and size of piston
Ring gaps are staggered when installed to minimize blow-by.
Compression Rings
Principal function of the compression ring is to seal the cylinder and
combustion space so gases cannot escape.
Made of gray cast iron
Some have inserts or facings for better seating (bronze or chrome)
The sharp edge on lower side, removes excess oil on the piston
down stroke, the tapered upper side distributes the remaining
oil on the piston upstroke.
If this ring is installed upside down, it will act as an oil pump
rather than a scraper.
Oil Ring Expander
Basically a spring that is placed in the oil grooves of the piston
prior to the oil rings being installed.
Used for distribution, removal of excess oil, and control of oil film.
Note: Different manufacturers use a variety of terms in their Tech. Manuals
to identify the oil rings, such as oil control, oil scraper, oil wiper, oil cutter, oil
drain, oil regulating.
Furthest from the combustion chamber, Regulate the amount of oil passing
between the skirt and cylinder wall.
Preventing excessive oil from entering the combustion chamber.
Types
Stationary Pins
Secured to the piston at the bosses. Connecting rod oscillates on the pin.
Uses one bearing surface.
Semi-Floating Pins
Secured in the middle of the connecting rod. Ends move freely in the bearing
surfaces of the bosses.
Uses two bearing surfaces.
Full Floating Pins
Not secured at either the piston or connecting rod.
May be held in place with caps, plugs, snap rings or spring clips.
Pin rotates in both the rod and piston bosses.
Uses four bearing surfaces.
Connecting Rod
Purpose
Transmits reciprocating motion of the piston to the rotary motion of the
crankshaft.
Transmits force of combustion on the piston to the crankshaft.
Transmits force to the piston from the crankshaft during the compression stroke.
Location
In the bore of the cylinder, between the piston and the crankshaft.
Crankshaft:
Forged steel with design determining the firing order for a given
direction of rotation.
Purpose
Converts the reciprocating motion of the piston and its connecting rod into rotary
motion.
Location
Supported by bearings below the block.
Block and main bearing caps are precision (line) bored.
Construction
Crank Journals
(Main Bearing Journals)
Induction hardened for durability and wear.
Crank Throw
3 parts- 2 webs and a pin
Provide attachment points for the connecting rods.
Construction Cont.
Counter Balance Weights
Heavy metal sections opposite the throws to offset the weight of the throws and
connecting rods. Fine balancing is achieved by drilling the counterweight.
Oil passages- Main bearings receive oil from the main oil galleries.
Passages are drilled between main and connecting rod journals
Rod journals receive oil from the drilled passages
Flywheel Hub allows a flywheel
To be bolted to the crankshaft.
Flywheel
Elastic Type
Fluid Type
Valve Assemblies
Valve Construction
Sodium can be highly explosive when it comes in contact with the atmosphere.
Seating edge of the face may be 30,45 or 60 degrees.
Seating angles are required to provide a positive seal.
Over half the heat a valve must dissipate, leaves through the valve face.
Face and seat surfaces may be hardened with a cobalt-tungsten alloy to
resist thermal damage.
Fillet (neck):
Constructed with the head and neck of a material
which resists heat
Hardened Tip:
Reduce wear from rocker arms.
Valve Springs
Valve Guides
Purpose
Provide a guide and
bearing for the valve
stems.
Also aid in conducting heat
from the stem to the water
jacket which surrounds the
guide.
Location
Pressed into the cylinder
head
Valve rotators:
not found on all engines.
Purpose
Rotate the valve, preventing carbon
buildup and hot spots that could
damage the valve and seating
surfaces.
Location
May be installed above or below the
valve spring, according to design
requirements.
Valve Keepers
Purpose
Lock the valve spring retainers to the valve spring.
Location
On top of the valve spring
Used to control the opening and closing of valves and fuel pumps/injectors
Camshaft: A long slender shaft with a number of projections called cam
lobes.
The timing desired determines the shape of the lobes.
Lobes are elliptical so the valves are opened and closed gradually to
avoid excessive inertial forces.
May be located low near the crankshaft, on the cylinder block or in/on the
cylinder head.
Purpose
4 stroke engine- normally operates the intake and exhaust valves, fuel
nozzles (spray nozzles), fuel injector pumps, fuel injectors or air starting
valves.
2 stroke engine- operates the exhaust valves, fuel nozzles, fuel injector
pumps, fuel injectors, or air starting valves
Machined surfaces
One end of the camshaft has a machined surface to which the camshaft
drive gear is attached
Timing
Camshafts time the events of the intake, compression, injection, power and
exhaust to the crankshaft.
Therefore the connecting drive must be positive, i.e. gear, chain or cogged
belt drive.
Cam must rotate once for each cycle of events.
Cam followers
Three types:
Mushroom type
Roller type
Hinged Roller type
Push rods
Purpose:
transmit the motion of the cam and lifter to the rocker on the cylinder head.
Location:
Between the cam followers and the rocker arms.
Rocker Arms
Part of the valve operating mechanism which opens and closes the intake
and or exhaust valves.
Purpose
To actuate the valves through the use of push rod or cam followers and the
camshaft.
Changes direction of motion only
On some engines a rocker arm operates the unit fuel injectors and fuel
injection pumps.
Each rocker arm actuates either one or two valves.
Location
Mounted on the head of an engine on a shaft, which acts as a pivot.
Bearings
2 general groups
Classification by construction
Precision type
Requires no fitting to the shaft.
May be split inserts which form a bushing when put
together
May be of solid construction.
Thrust type
Same as precision type except babbitt is carried on over the edge of the
shell, and is machined to give it a surface to absorb the axial thrust.
All sliding contact bearings will support radial loads or combinations of radial
and axial loads.
Drive Mechanisms
Identifies the group of parts which take power from the crankshaft and transmits
that power to various engine components and accessories.
Camshafts
Pumps
Blowers
The drive mechanism does not change type of motion but it may change
direction of motion.
Types of Drives
Gear Drive
Consists of various helical gears arranged at one or both ends of the engine.
Most common type of drive mechanism.
Chain Drive
Cogged belt