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    © All Rights Reserved
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    36 views33 pages

    Print F Maintenance STD

    Uploaded by

    soelist teo

    Copyright:

    © All Rights Reserved
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    ENGINE ‘ a MAINTENANCE STANDARD 621501 INTAKE AND EXHAUST SYSTEM ‘Turbocharger ....... 14-002 ENGINE BODY Cylinder head Valve, valve spring an 14-003 valve guide . 14-004 Rocker arm and shaft 14-006 Crosshead and guide . 14-007 Cylinder bIOCK .....s.eccssesseesees+ 14-008 Cylinder liner ..... 14-010 Crankshaft . 14-011 Camshaft : 14-012 Cam follower and push rod 14-013 Timing gear fee 14-014 Piston, piston ring and piston pin ...... . 14-016 Connecting rod seeesessees 14-018 Flywheel and flywheel housing ... 14-019 LUBRICATION SYSTEM Oil pump Main relief valve Oil cooler by-pass valve, 14-022 . 14-026 regulator valve . 14-027 COOLING SYSTEM ‘Water pump 14-029 Thermostat rennnnnnnnnnnnnnnes M4030 14-001 @ INTAKE AND EXHAUST SYSTEM TURBOCHARGER KTR110 Engine No. 10001 - 10757 ———— Ce ey +4 a a 1 | o 1 8 10 2 a 4 14-002 ® 621501 621501 Unie: find ve. checkin cra reed Sagar Repair it 1 | nd pay (Ploy in axial direction) Se oa ae Baan (oats =e (oot Radial play (Play in radial direction) O28 0.86 0.80, Replace 2_| Rasial play (Play in radial diction) 10.0010 - 0.01731 10.0236) bearing parts: Sandra Toles ena i size Shaft Hole, ‘Shaft Hole 4. | outside ameter tour ean Sete : Par dametr feta owe weaet "9 23 10.0016) (90,0008) 22.92 23.03 poms, | SRB) S| ates | asora eo aon, | ae lnerionetsofjurtinarng | \35,) | aap | wRiBlo | age | soe id tr hat Bi : eo + | Outsic ter of whee! shaft (0.00171 (00011 Band ot whol sna Rep 07 BS tl nit an sonics Sand Tolan repair sue Width Groove Width Groove 5 | Tiree of moet bearing “oe | cone s | cbt: | citi | age | soe con | wo | elitay | cotate cl ae, | ae rors | 2 | cabin | abit] tae | aos $8" | today | Mesa! | FRR | ebb. | ln atin, volte 6 | sen of ting aa, | am atone | ye | ea | aii | us | hee ST | clay | ahs Be | abr | oes aman oar Ta FSG ones 7 [Sars Teterane (in 30 10.9071 Pelee Teng rans Tar 5 [aera 292 0¢84gm 88704 I aang torque TH Pe 2 | a ql 2.8038 tam (203-2634) Tightening torque of turbine a » [mama sos 0atom 2s a86 nb) Tahen 1a | Raabe rane ot eroharaer s0s08tgm 2s eR) 12 | Tieng orgu FV band ote oa 0-1kgm (68-7240) 14-002-1 @ 621501 ENGINE BODY CYLINDER HEAD Tighter 19 order of cylinder head mounting bolt rectors Ui mm ey to check tem cera ame apart 1 | ostrtion ot xine ad mouting apa, Soe 000010 0023 0.9 (0.098 aa Tenis cote 2 | Protas of onto Standard: 408 ~ 56 (0189 ~ 0222 Sena foal tot Ne Over Torso Fanoe : Tram | a= tog weer | tests rot marta Tatsering oye of ender nad vrohon ote mug ok Toa an eras 2a ign |215~72510m | Toten » | mesg ak ane od arsoen | fh (ero) MeN. ‘molybdenum dieutide) tihten wth bole seastop | Patten wh | ap — ar D > Fan] 8-7etan (cooky lutea Tse Tone «| Tahtnng rae of nox hoer et ‘mounting Dot (6.8 kgm [49.2 fib) 6 — 7.5 kgm [43.4 — 54.2 ftlb] 5 | Teenie ouster Sstomca7sney | 38—arnamias4— 296,001 | matohien «| Taher crue ct omer abe ovum aaeney | 9848 wgmiasa— 28K Titers eaue of evinde hand ~ Notte case 7 | Baten ra os tam 96 Ahi c4— 06 Kym i29— 42) 14-003 VALVE, VALVE SPRING AND VALVE GUIDE c —s lo O- 212010748 14-004 621501 621501 Units_me in} Wo. Check tem cite needy Vave | Stndordsze | _Tokrance | _Repat ni ao 0.70, Replace valve. + ancrtt te sin voters || ga [ia | Sete 31 on Eeaurtvave | 8 St | a vane Standard de epi t 2 | Thickness of vaive lip Intake valve 2.4 (0.094) 1.9 (0.078) Replace valve. Exhust abe 2.is 008s) 1,008) vane Standard oe Toiorance Rape 2 | Vane seat angle Inte vane oo ad Topics valve vote sot Exhaust va s ow wana vwioaen | 9B 9ST Cus cometerofvae stem SATE | reco voe Exot ave rorosea | —0Q@eir noone oon 70 008 Before inserting ee ee eee Inside amar of vaho gue eee pe Aer inserting 100984) ats F008 ‘ Vate Standard deorance | Grane it leerance between valve guide ane Intake valve 0.034 ~ 0.074 022 Roplace valve i dam eer vowe aid ant rake cacors— oaczn ceooaey —_| Bence se ‘Exhaust valve. 0.063 = 0.100 0.24 *t [0.0025 — 0.0038) 10.0096) Bend eva sem Repair init 0.02 (0007 (ondeated uno fr 1002887) | Relace veh Standard dee Teeaneo 5 | Protusion ot valve gue fei 7310806) 202 200078) Stndard ete Tepaitit Taste | aed ire | 0 Freetown] TESS | PERE [ree eran] PHS | ive pi our | on9 237kg , [mies Gees, | 2x7 19221 s.01200 a re org vet 17g (tS, | 201288] ee00s0n as Saurence of vate sng epi init: orbot oh 7 the exhaust valve hes been used for mare than 10,000 hours, replace with a new part. Reference: Inside diameter of supply valve guide Before press ting: 10:294! mm [0.204900 np Alter press fiting: 10:4 0.011 mm 10.984 + 0.00004 ini 14-005 ® ROCKER ARM AND SHAFT a 2 woz Toca loside ameter of rocker arm bustin 0.087 Fo 0034 ‘Replace + [se oro ram ig aa) eee) (Se edhe om baking 2028s — bows 02012 om xs i0005) sla arm 3] TBotenes Screw eeknat Tighten 14-006 621601 621501 CROSSHEAD AND GUIDE 4 my 1 ae >. recxz010768 Unit: mm fin) we check tem cites Temesy Sane ae Towance apart + | pep ot crosshead stm 320248 Feafteoria] | oz oz0n reploce Inte deter of consoad 1 ae] pos te0%%8) | ans7roaen 2 Outside dometer of corsshend aude 11 (0499) B07 [90001] | yaasr0aan 3 | Pruson ot cused gue weorise | ozets oom rei 4 | Fatenng ou of eaten cut 8206 km f994 477 Thien 14.007 D 621501 Unit: me ind 1 | Pistonion of onder nova Sincere epa t era my Soaow6- 9008 stews | Sn vas sons tan sox Stn rams ___ dae, ee ~Boae one | arm Sc inom awe 2 const Gucrsinar TOTO Sven ons 0 wad SaTaRT Thickness of main: only 48100771 0.060 [-0.0023) Dene on ro asta et SRS Journal Stenderd size Tolerance Repair lirnit Replace weitedaneerot [Het er 8 main bearing, Only 148 16.8271 40.130 [+0.0051] 148.25 (B.898) os oor 14 | side diameter of camshaft bushing soir" +9025 1-0 0008) . remlace rose 5 | Inside diameter of camshoft bushing 65 [2.559] 0.040 [40.0018] 65.15/2.565) camshaft o te od bushing ae Tone = ote rect main moon | tentang 6 | cap bolt (Cost thread area with ware Bes htet Dates | etahcnwaneo [90-20 nae Sign tes Sasa Fs BNET pre «| Sires eesgeseen Repirii 0405 ol ¥ Twemain apboltcan be tightened a maximum of times, Make a punch mai on he bolt head wach time Tonnes 14-009 @ CYLINDER LINER rez1201028 Unit: mm tnd No. Check item itera emedy Rapa finder oer 1 | rottusion of ender tiner lo range: 007 0.1 (0.0027 - 0.0059) Srrepie or ‘enlace syne tock Rank | Standard size Tolerance 2 | isi clametr of eying ner s “yoi65 140-12 18621 on Repiace “wo 18 20080(-0.0018) ender tine ‘ 140 16.6721 +0.021 {+0.0008) 10.16 (95221 {Only Lis, Sipalied Outside diameter of cylinder tiner Standard size Tolerance {Counter bore) oto 4 5 792162701 010 10.0029) Replace Ceara betweon cylinder ner sandard:0-0.18810--0.006e1 cinder ine fend book (Counter bora) oreylindor Bode shee Toteronce Outside diameter of eyinder liner Stenderd si i Replace {Counter bare nota) "00901-00008) ender liner 1512 16:346) Jos0(c00008) ‘ ‘Standard interfer Interte fi reper Interference betwen cylinder liner fendard interference interference limit oylinder tines an block (Counter bore bottom - repair or 0020.12 (0.0008 000871 0.02-01210.0008- 004 | Snderbiosk Outside diameter of eylinder liner Stondord size Tolerance Replace {Oring port ob (-000001 ptnder ter : 1816221 20.049 -a90%61 ° Casa ‘rh Replace Snablost (Oring pan 0024-094 (0.001-0.90371 oy er book 14-010 ® 621501 621501 / AA yo oss | ROS exrseosa Detlef @a¥60 Unit mm ink Ciara Romedy Standard Repair init Peper End lay Seton 0.100.318 10066-00021 4.50(0.0198 bearing or reploce Standerdsiew | Tolerance | _ Renartimit sto | 180016271 17.98 16830) 025 Us.000se! | 14775158171 107.73 168211 Curse carota of mai journal Repair by osoUsiooien| 14750158071 10748188111 | sing over 0.75 u.8.0.0296] | 147.256.7971, 447.23 16.001) [Se buat 10051003901] 147.0016767) 1469615797 Repair nit Aoundnese afin journal @=a010,0- 0.00081, Journal Standard clearance Ciaran init caingunder Clearance of main No. 4 only 0.130 ~ 0.195 (0.00076) 0.25 (0.0099) ‘size bearing iourna or replace Except Noa | _000-076510008-00068) 922100087) main bearog _ ~ Correct Sorte Suroce roughness of mein journal 1085 uraceoughress at porion: 328) roughness of " ‘ per orankshatt jour Standardize | Tolerance | _ Repair int sro | rooo0rseen 6.06188821 Outside dameteroferankpin | 926u.Ss00088)| 99.278 138271 S28515 8221 | aopar by Journal osousisown| sosorsarl | (3%) 9.383813] _| using under 075 u5,002961| 962568071 ones] .s01asoas_| Se Pens _ voous.ose4i| “9500198971 9.8 (3.295 Repair iit Roundness of crank pin journal = — 2007010 -ococa) vender elenrance earanes i Replace Clearance of crank pin journ: Stendard ek a n connecting (048 ~0.116 (00019-00085 025100102 rod bearing 7 Correct surface Surface roughness of erartshaft pin 085 (surface uahness aR portion: 32) roughness of Journal * p crankshaft 7 _| ocr Stancard ane Repair nie Saghtnes fa main ournal ‘ within 0 ~ 0.09 [0 - 0.0035) 0,09 (0.00351 Replace Seaightness oF wo main ournal | _wihin = 0.0510 000191 0051000181 _ Tare ange 33-95 kom ‘sep rskomi6s2tum | ea ekg ‘ronk pulley mounting bot oT when ots 2nd sep asokgmivenstiot | eng vaesttb: [inom mn 749-780 xg Bats No sre step reagm ert | AS BONN Tightening torque of vibration Tyowmuae_eor damper mounting bolts Mz 10 kom (72.4 ~ 867 Rb) 14-011 Judgement standards for judging if crankshaft can be used again If it is impossible to measure all the Items in the MAINTENANCE STANDARD (including roughness), use the following conditions to judge if the crank- shaft can be used again 1. If' more than 60% of the overlay of the pin bear- ing has been lost after about 4000 hours of op- ration due to the entry of dust, the crankshaft journal surface has probably become rough, so grind again or replat 2. On engines where the oil filter may have become clogged because of deterioration of the oil or ‘entry of water into the oil pan, there are probably scratches or increased roughness on the journal surface caused by dirt, so grind again or replace. 3. If the main journal or pin journal has seized, the ‘crankshaft hardness will have been lost because of the high temperature end the strength may have dropped, so do not use such parts again (There is danger that the crankshaft may break.) 14-011-1 ® 621501 CAMSHAFT FERAL EAA Right bank camshatt 1 2 3 / Lote bonk camshat 4 Section AA — rie em te we cutien a reer Sonne + | espe ae — fepeco ws 0.1 — 0.25 [0.0033 — 0.0038) 0.36 (0.0142) pate Sond ee Townes . Outside diameter of camshaft journal eplace cao wee 2s aot ote 2{ me Sonar cowace cn i cima cn joel oni ss (oun a00on ors mote 2 | eae etcansten Teva it 00406 To nse oe — 4 | cam height intake 55.48 (2.184) | 201 (2 0.0029) | $5.08 (2.168) | "==" Siew | sere cm | sem 14-012 621501 621501 CAM FOLLOWER AND PUSH ROD ezvzo081 Ut: ne check ier fereéy Sanerdee Tomance Teer i , [one contrctemitowenn TT) aa | — ae Toe dame ofcam towerannoe | menessy | F202 ¥80000) | zor oar 2 | ouside diameter of can voter crue) | 1925[/9988) [asia Ise dota of om aller veriason | {9238({2@5) | sae rosea 3 reotce ‘use rae of am eller n raesiosen | comets occa) | r2s6(00n «| rac fps bal one en Fal geal 5 | racios of od soc ena 134 0828 Saal Soore] 6 | bens otoan oa Ropar kn 090.917] Toten nou 7 [Fang te ws 45 004gm (6-098) Tatton 14.013 ® TIMING GEAR WITH MECHANICAL GOVERNOR ({D475A-2, HD785-3, WA800-2, HV700-1, HV700-2) 14-014 ® 621501 621501 Unit:_evm in) easurng Geass Standord size [Repair ii 2 [SSEMRAL oe _fpails-smenP ste © [Enanaea Sm [SE-B potesrn c | Ronan om [ataet— 23¥ta|osieozs] 2 [RSnewae est [ates Setnpstors [Ropar Sor 8h <8 poten ~ | Pateanstenn ones + [Beara ae" on oa ~ 2 eerea| o_ [Samaras 8h Sstoman » | ERERSLS Pan bbls Ser pste one 1 [eaitgiaierm’ tlt Spe toon 1 | Empat Soe See et SiBaps tonne x [Seraanst | date tn, peonl [ T stone sig Standard | Clearance + | Sopomeemceyra ite gt — rece soa | Sentea| POT ee ea| wae | 2 | Sevusbomgna soins | SESS] POY | ae ee| eee wart canons 4 | en play of sub ater gear ae Oy oaroorsn senses we 3 | End pay ofijecton pump dive gear 0a oy oarooren beara 6 | End pity of pump drive gear 0a oarooren 7 | tnd play of accessory dive ger (efao oe, oaroarsn 14-015 ® WITH ELECTRONICAL GOVERNOR (HD785-3, HD985-3) 14-015-1 @ 627501 Urits_mm fn} 621501 ‘heck Remedy Pagar andre ee point Stonserd Crankehaf gear and ona — 0405 2 | Femoiniler gear Lore) [9.0056 — a0t67] wp | Pitain idler gear Smal) | 0125-088 and sub idler gear to.0089 - 0.0143) ve__| Femain ialer goa Sm 0.125-0363 | anaReamahate eer” _|(0.0049-0.0143) va | Fecamshaft goer and 0.138-0.356 ecseseary drvegear (0.005 -0.0159) ~ Ider gear Smat) andl 0.125 0.368 ‘© _| fenjectan pump drive gear 10.0049 0.0143 Backlash of each geers |_| Remain ier gear (Smt) ona) 0.052 — 0481 Replace (*: Bowen spur gears) trata pump deve gear (00025 — ora Femain der ger (Smal) ana) 0.137 ~ 0421 9 | citbumo drive acer foooss — acres] 1 | craakshatt gear end o.141 — 0425) Uimoin ler gear Large) (00086 — 0767] ~ | Lmeinicer gear Seat) | 0.725-0.88 “| nd Scamanoht geo roo049 - 0.0143) | Emein ler gear (Sma) onal 0125 0.369 | injection pump arve gear (0.0049 - 0.0143 Tk | Eilestion pump dive geor ror compressor dive gear standard se Standard Clearance bowen main iter geor snk - Replace onnsy-omom | 2088 aoarn | Te ome boshin 56 12.206) tottos 0082) (0.0076) . ‘earance between sub isler 2018 -00m ‘ear bushing nd shat 6 (2.2081 tanta} 0.0781 Repair init End play of main idler gear (0.0028-0.00321, estos) End play of su ier gear 10.08 Ogee ost001571 entce ts End play of nection pump deve gear 009, oe ay os (00157) beer Ena play of ol pump drive goat op 08, 000187) End play of accessory drive gear 0 fo0rs7) 0.004 — 0.0187) 14-015-2 ® PISTON, PISTON RING AND PISTON PIN 14-016 ® 621501 nit: em fn No. Checkitern citer Remedy Rank | Standard exe Tolerance Repair limit Replace aan |-0.0007| 1 | Outside ameter af piston fatright |S Mower) 2005 oonsss_| 1996515590) _| piston fot antes fo boss) | vwoissr2) ae oem | 1386 i550) Meoauroment Stondord Clearance Ne. Toeation clearance Tit 042-0857 2 Top ring toores-o.o224) | 1910024 Ireptace Clearance at iaton ring end gap |} —to.ores -oazzs) |__| Rerlece 3 2nd ving one cama) | 19t00884) 037-082, 4 ot ring fostiecoosea | 101008841 no. | Meer] standare |_Tolerance ‘tearance 2 icaattin | 8% | ing | Paton tn I ans 4 2a | (00005 2 | Top rn _dudge wth groove wear gu | cooaes | gi, | “een owe Replace Glance von psn ng ae ere orplston 3. | anaing | sadétay | 251) de wi roove wer asuoe |THE robot =eer0, | +0000 Jon coring | 4. | | at |022- 095] gag 4 | oitein ‘gact (0.4871 | (Panta acco | ccczay | (200951 ‘Standard Tolerance Standard 5. | clearance between piston and see [Shan ow cteorance | “mt _|Repace piston pin e2 fo 10 j[aoos oom] 036-0051 | 0.10 | orpiston pin «2.0475 | 06 (-0.0023i| 2.085 00013} |to.0014-o.00201 | 10.0039) sion Piston portion @ Carbon deposi Thickness: 1m (0.03941 or more! eased ie ian ton scene a 14-017 ® CONNECTING ROD 14-018 8 Tightening dor OO 621501 nit: en tnd wo. check tem xtra Fema Sandee Toman apa amie | Replace «| ns trates of connecting ro : hing Challe busng sepa “gous age son 20811 Cunrnch neuen conning oa Sander deorance cesar ini apace Seal end busing and piston pln 090-0055 at Bathing o jooo%e—o0cen 00041 sisonin ‘san danerorpauminghanen Sunder ee Toerance Tepe co inside ameter of mourn hola netting 2 oa

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