IMPORTANT A. The Catalogue covers our product range. However new models are being constantly added. Please contact us for any model not shown in the cata- logue. B. Piston Ring set number given against respective Piston model is represen- tative of the complete range of rings manufactured. C. Reproduction of this Catalogue in whole or part is strictly prohibited. D. While every precaution has been taken to provide accurate information, we accept no responsibility for any inadvertent errors/omissions in the cata- logue. E. Engine Manufacturer’s brand names and part numbers have been given for reference purpose only and are not intended to imply that our parts are used as original equipment. F. Pistons and Piston Rings are also available in oversizes. Please specify the required oversize after the part reference number. G. Our products are warranted against manufacturing defects upto prefitment stage. The company will repair/replace defective parts returned freight pre- paid within a period of 90 days from the date of sale invoice. No other warranty or liability is either implied or undertaken. It is a precondi- tion of sale that the buyer accepts this warranty policy. Volume XII August 2016 CONTENTS • Introduction 2 • Nomenclature - Piston Assemblies 4 • Piston Types 5 • Technical Terms of the Pistons 6 • Piston Shapes 7 • Ring Types 14 • Ring Set Type/Reference Table 15 • Piston Assembly - Do’s and Don’ts 17 • Instructions for use of the Catalogue 18 • Technical Data 19 • Index - Alphabetical 187 • Index - Diameter Wise 207 1 NOMENCLATURE PISTON ASSEMBLIES ENGINE MAKE/MODEL AC : AIR COMPRESSOR DI : DIRECT INJECTION IDI/FT : INDIRECT INJECTION / FLAT TOP NA : NATURALLY ASPIRATED TC/A : TURBO CHARGED PISTON TYPES CONV : CONVENTIONAL (PARALLEL) GROOVE KS : KEYSTONE GROOVE/TRAPEZOIDAL GROOVE SHIM : TOP GROOVE PROVIDED WITH STEEL SHIM RCP : RING CARRIER PISTON/ALFIN PISTON RCP (KS) : RCP WITH KEYSTONE GROOVE STRUT : PISTON PROVIDED WITH STEEL STRUT AT THE SKIRT/PIN BORE STRUT-CUM-RCP : RCP PISTON PROVIDED WITH STRUT WT : WINDOW TYPE (WITH AS CAST PIN BORE RELIEF AREA) GT : PISTONS MADE OF NEW THERMODUR ALLOY CONTAINING HIGHER PER- CENTAGE OF NICKEL AND COPPER OCG : OIL COOLED GALLERY PISTON KS LITE : ULTRA LIGHT GASOLINE PISTON DOUBLE RCP : DOUBLE RING CARRIER PISTON HA : HARD ANODISED RING GROOVE PISTON PISTON DIMENSIONS CH : COMPRESSION HEIGHT DH : DOME HEIGHT (INDICATED IN ‘+’ ve / CAVITY DEPTH IN ‘–’ ve) TL : TOTAL LENGTH CAVITY VOLUME : INDICATED IN ‘( )’ (VALUES ARE AS PER DRAWINGS, CALCULATED WITHOUT CONSIDERING VALVE POCKET VOLUME) 4 PISTON TYPES CONVENTIONAL (CONV.) RING CARRIER (RCP) WINDOW TYPE (WT) OIL COOLED GALLERY (OCG) GT STRUT - CUM - RCP KS LITE HARD ANODISED DOUBLE RCP RING GROOVE (HA) 5 TECHNICAL TERMS OF THE PISTON Piston crown Interior combustion chamber Ring carrier Edge of the piston crown Top land Compression ring groove Ring land KH– Accumulator groove Ring zone Bottom of the groove (CH) Recessed ring land Upper and bottom flank Compression Height Oil ring groove (TL) Oil return holes Total Length Total Piston pin boss Pin bore Skirt Retainer/circlip groove Distance between bosses Bottom of the skirt Piston diameter 6 PISTON SHAPES 7 123 456 789 10 11 12 8 13 14 15 16 17 18 19 20 21 22 23 24 9 25 26 27 28 29 30 31 32 33 34 35 36 10 37 38 39 40 41 42 43 44 45 46 47 48 11 49 50 51 52 53 54 \\MEGA2\Product Catalogue 2016 (July)\GB 5985_PRP Product Catalogue 2016_Jan 26'16\Link 55 56 57 58 59 60 12 61 62 OP 13 RING TYPES COMPRESSION RINGS OIL RINGS Shape Nomen- Description Description Nomen- Shape clature clature C Plain Slotted Oil Control SOC Top Top T Taper Face Parallel Bevelled PBO Top N Napier Face Cross Bevelled CBO N (I) Interrupted Napier IB Inside Bevelled High Tension spring HTPL loaded plain Top IS Inside Stepped High Tension spring HTCR loaded chrome *HTPR K Keystone/Half/Full Chrome Oil CRO CR Chrome plated Chrome oil with CRO (E) Barrel honed expander SSR Steel segments High Tension OD & ID HICR 4 Pcs. Chrome platted Spring *HIPR (Cord Rings) Loaded CRT Taper Chrome Steel Oil Ring SOR Top -6 Pcs (4 Steel rails, 1 Spacer, 1 Expander (Duaflex Rings) Top RT Reverse torsion Rikvent RIKVENT -3 Pcs (2 steel rails and 1 Expander) CRK Chrome plated Diesel Vent ‘M’ DVM Key Stone Steel Oil Ring KMO Key Stone HICR Ring with Key HICR(KS) Plasma Moly Stone Cross Section GN Gas Semi inlaid SIM Nitrided Moly CR(I)K Key Stone Chrome Semi inlaid SIC (Inlaid) CPC CPC Composite Plating Thin DVM TDVM of Chrome IP Ion Plating *Profile Ground NOTE: - (E) stands for Expander which is fitted behind the rings, wherever applicable. - Suffix ‘SS’ to nomenclature denotes special RIK20A material. - Prefix HP stands for High Power Cam Coiled Steel Ring - Suffix GN denotes Gas Nitrided - Suffix W denotes Wrap around Chrome Plated (Chrome Plating on all the sides) - Suffix CF denotes Copper Flashed - Suffix MO denotes Moly Coated - Suffix Sn denotes Tin Coated - (I) denotes Inlaid 14 RING SET TYPE PL : Ring set with compression/oil rings or a combination of both without any plating. CR : Ring set with top one chrome plated ring. TC : Ring set with two chrome plated compression rings or a combination of compression/oil rings. SSTR : Ring set with top ring made of RIK20A (Special Steel) material with HTCR oil ring. SS3C : Ring set with three chrome plated rings and with top ring made of RIK20A (Special Steel) material. S2S : Ring set with first two compression rings made of either RIK20A material and/or special heat treated (RIK-10) alloy or combination. ST3C : Ring set with top ring made of Hi-Power stainless steel material and with three chrome plated rings. TGN : Ring set with gas nitrided, Hi-Power stainless steel material top ring. SSPR : Ring set with Profile Ground HTCR/HICR Type oil ring and with top ring made of RIK20A (Special Steel) material. SSPR-WX : Ring set with Profile Ground HTCR/HICR Type oil ring and with Wrap around chrome plated top ring made of RIK20A (Special Steel) material. SS3C-WX : Ring set with Wrap around chrome plated top ring made of RIK20A (Special Steel) material and with three chrome plated rings. EXT : Ring set with expander beneath some rings e.g. Ford 3600. RIKVENT : Ring set with Rikvent ring as an oil ring. HPVENT : Ring set with Rikvent ring as an oil ring and a Hi-Power stainless steel material top ring. 3S3C-DLX : Ring set with three stainless steel chrome plated rings. 3S3N : Ring set with three stainless steel, gas nitrided rings. HTCR : Ring set with HTCR ring as an oil ring. HTPL : Ring set with HTPL ring as an oil ring and plain compression rings. IDCR : Ring set with HICR ring as an oil ring. DVM : Ring set with DVM ring as an oil ring. SUPER DVM : Ring set with Hi-Power stainless steel material gas nitrided top ring and with DVM oil ring. SSIR(K) : Ring set with top ring made of RIK-20A (Special Steel) and keystone HICR type oil ring. SSIR : Ring set with top ring made of RIK-20A (Special Steel) and HICR type oil ring. SS(I)IR : Ring set with chrome inlaid top ring made of RIK-20A (Special Steel) and HICR type oil ring. DVM(I) : Ring set with chrome inlaid top ring and DVM type oil ring. DVM(CR) : Ring set with chrome plated DVM ring. HPPR : Ring set with Hi-Power stainless steel material as top ring and Profile Ground HTCR type oil ring. SSM : Ring set with top ring made of Ceramic Plasma (Moly Inlaid) special steel material. STMR : Ring set with top ring made of Ceramic Plasma (Moly Inlaid) coated Hi-Power stainless steel material. HPCPPR : Ring set with Ceramic Plasma (Moly Inlaid) Hi-Power stainless steel material as top ring and Profile Ground HTCR type oil ring. CPCR : Ring set with Ceramic Plasma (Moly Inlaid) top ring with HTCR type oil ring. SSCPCR : Ring set with Ceramic Plasma (Moly Inlaid) top ring made of RIK-20A (Special Steel) material and HTCR type oil ring. 15 RING SET TYPE (Contd.) SSCP2CR : Ring set with two Ceramic Plasma (Moly Inlaid) rings with top ring made of RIK-20A (Special Steel) material and HTCR type oil ring. SSCP2IR : Ring set with two Ceramic Plasma (Moly Inlaid) rings with top ring made of RIK-20A (Special Steel) material and HICR type oil ring. SSMCR : Top Moly with Rik 20A (Special Steel) chrome plated HTCR type oil ring. CPDVM : Ring set with Ceramic Plasma (Moly Inlaid) top ring and DVM type oil ring. MDVM : Ring set with top ring made of Moly Inlaid Special Steel Material with DVM oil ring. SMDVM : Ring set with top ring made of Moly Inlaid Steel Material with DVM oil ring. CP Plus : Ring set with top ring as Ceramic Plasma (Moly Inlaid). CP Gold : Ring set with top ring as Ceramic Plasma (Moly Inlaid) and oil ring as DVM oil control ring. CP Platinum : Ring set with top two rings as Ceramic Plasma (Moly Inlaid) and oil ring as DVM oil control ring. CPC 200 : Composite Plating of Chrome in Top Ring. CPC 500 : Composite Plating of Dimond in Top Ring. TIP : Ring set with Top Ring Ion Plated (PVD). RIP : Ring set with Rails Ion Plated (PVD). TRIP : Ring set with Top Ring & Rails Ion Plated (PVD). REFERENCE TABLE - CAST IRON RING ALLOYS SPR COFAP GOETZE PERFECT NPR DIN TP ISO (RIKEN) CIRCLE 70909 6621/3 RIK40 MF10 K1 (STD) 110 – STD – SUB CLASS K3 (STD) 12 RIK20A– K7 (KV1)* – NIPPALLOY G6* – SUB CLASS (KV2) G7 51/53/54 RIK10 MF18 K4 (IKA) – ACICULAR G3 TP01201* SUB CLASS K8 (F13) CAST IRON 24/F-14 SPR02 F14 MC 32 MC 32 RIK25H KV4 MC 56 MC 56 * Material not fully similar to ISO REFERENCE TABLE - REFERENCE TABLE - STEEL RING ALLOYS PISTON ALLOYS SPR FMGIL MAHLE SPR ISO (RIKEN) 6621/3 KS 1275 CSA 12/FM 120 MAHLE 124 RIK SS1 MC 67 KS 281.1 CSA 18 MAHLE 138 RIK SP2 MC 64 HA1 CSA 24 MAHLE 244 RIK SP3 MC 66 KS 1295 S2N MAHLE 142 16 THE PERFECT PISTON ASSEMBLY HOW TO HANDLE IT DO’S DON’TS 1.0 Always rebore the cylinder to the diameter of the 1.0 Never gauge the accuracy of the cylinder bore by piston plus the specified cold clearance (CL) as merely moving the piston within the cylinder.